Heating element

ABSTRACT

A heating element for a vaporizer cartridge is provided. The vaporizer cartridge may include a reservoir containing vaporizable material and a wicking element in fluid communication with the reservoir. The heating element may include a heating portion, a cartridge contact, and a leg. The heating portion includes at least two tines spaced apart from one another. The cartridge contact may be in in electrical communication with a power source. The leg extends between the heating portion and the cartridge contact. The heating portion may be crimped around the wicking element such that the heating portion secures the wicking element to the heating element and contacts at least two surfaces of the wicking element.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.62/913,135, filed on Oct. 9, 2019, and titled “HEATING ELEMENT,” U.S.Provisional Application No. 62/745,589, filed on Oct. 15, 2018, andtitled “HEATING ELEMENT,” U.S. Provisional Application No. 62/812,161,filed on Feb. 28, 2019, and titled “CARTRIDGE FOR A VAPORIZER DEVICE,”and U.S. Provisional Application No. 62/747,099, filed on Oct. 17, 2018,and titled “WICK FEED AND HEATING ELEMENTS IN A VAPORIZER DEVICE,” theentirety of each of which is incorporated by reference herein.

TECHNICAL FIELD

The subject matter described herein relates to vaporizer devices,including heating elements for vaporizer devices.

BACKGROUND

Vaporizing devices, which can be referred to as vaporizers, electronicvaporizer devices or e-vaporizer devices, can be used for delivery of anaerosol (or “vapor”) containing one or more active ingredients byinhalation of the aerosol by a user of the vaporizer device. Forexample, electronic nicotine delivery systems (ENDS) include a class ofvaporizer devices that are battery powered and that may be used tosimulate the experience of smoking, but without burning of tobacco orother substances.

In use of a vaporizer device, the user inhales an aerosol, commonlycalled vapor, which may be generated by a heating element that vaporizes(e.g., causing a liquid or solid to at least partially transition to thegas phase) a vaporizable material, which may be liquid, a solution, asolid, a wax, or any other form as may be compatible with use of aspecific vaporizer device. The vaporizable material used with avaporizer can be provided within a cartridge (e.g., a separable part ofthe vaporizer that contains the vaporizable material in a reservoir)that includes a mouthpiece (e.g., for inhalation by a user).

To receive the inhalable aerosol generated by a vaporizer device, a usermay, in certain examples, activate the vaporizer device by taking apuff, by pressing a button, or by some other approach. A puff, as theterm is generally used (and also used herein), refers to inhalation bythe user in a manner that causes a volume of air to be drawn into thevaporizer device such that the inhalable aerosol is generated by acombination of vaporized vaporizable material with the air.

A typical approach by which a vaporizer device generates an inhalableaerosol from a vaporizable material involves heating the vaporizablematerial in a vaporization chamber (or a heater chamber) to cause thevaporizable material to be converted to the gas (or vapor) phase. Avaporization chamber generally refers to an area or volume in thevaporizer device within which a heat source (e.g., conductive,convective, and/or radiative) causes heating of a vaporizable materialto produce a mixture of air and vaporized vaporizable material to form avapor for inhalation by a user of the vaporization device.

The term vaporizer device, as used herein consistent with the currentsubject matter, generally refers to portable, self-contained devicesthat are convenient for personal use. Typically, such devices arecontrolled by one or more switches, buttons, touch sensitive devices, orother user input functionality or the like (which can be referred togenerally as controls) on the vaporizer, although a number of devicesthat may wirelessly communicate with an external controller (e.g., asmartphone, a smart watch, other wearable electronic devices, etc.) haverecently become available. Control, in this context, refers generally toan ability to influence one or more of a variety of operatingparameters, which may include without limitation any of causing theheater to be turned on and/or off, adjusting a minimum and/or maximumtemperature to which the heater is heated during operation, variousgames or other interactive features that a user might access on adevice, and/or other operations.

Various vaporizable materials having a variety of contents andproportions of such contents can be contained in the cartridge. Somevaporizable materials, for example, may have a smaller percentage ofactive ingredients per total volume of vaporizable material, such as dueto regulations requiring certain active ingredient percentages. As aresult, a user may need to vaporize a large amount of vaporizablematerial (e.g., compared to the overall volume of vaporizable materialthat can be stored in a cartridge) to achieve a desired effect.

SUMMARY

Aspects of the current subject matter relate to a heating element foruse in a vaporizer device.

A heating element may include a heating portion and at least two legs.The heating portion may include at least two tines spaced apart from oneanother. The heating portion may be preformed to define an interiorvolume configured to receive the wicking element such that the heatingportion secures at least a portion of the wicking element to the heatingelement. The heating portion may be configured to contact at least twoseparate surfaces of the wicking element. The at least two legs may becoupled to the at least two tines and spaced apart from the heatingportion. The at least two legs may be configured to electricallycommunicate with a power source. Power is configured to be supplied tothe heating portion from the power source to generate heat, therebyvaporizing the vaporizable material stored within the wicking element.

In some implementations, the at least two legs includes four legs. Insome implementations, the heating portion is configured to contact atleast three separate surfaces of the wicking element.

In some implementations, the at least two tines includes a first sidetine portion, a second side tine portion opposing the first side tineportion, and a platform tine portion connecting the first side tineportion with the second side tine portion. The platform tine portion maybe positioned approximately perpendicular to a portion of the first sidetine portion and the second side tine portion. The first side tineportion, the second side tine portion, and the platform tine portiondefines the interior volume in which the wicking element is positioned.In some implementations, the at least two legs are located away from theheating portion by a bridge.

In some implementations, each of the at least two legs includes acartridge contact positioned at an end of each of the at least two legs.The cartridge contact may electrically communicate with the powersource. The cartridge contact may be angled and extend away from theheating portion.

In some implementations, the at least two tines includes a first pair oftines and a second pair of tines. In some implementations, the tines ofthe first pair of tines are evenly spaced from one another. In someimplementations, the tines of the first pair of tines are spaced apartby a width. In some implementations, the width is greater at an innerregion of the heating element adjacent the platform tine portion thanthe width at an outer region of the heating element adjacent an outeredge of the first side tine portion opposite the inner region.

In some implementations, the vaporizer device is configured to measure aresistance of the heating element at each of the four legs to control atemperature of the heating element. In some implementations, the heatingelement includes a heat shield configured to insulate the heatingportion from a body of the vaporizer device.

In some implementations, the vaporizer device further includes a heatshield configured to surround at least a portion of the heating elementand insulate the heating portion from a body of a wick housingconfigured to surround at least a portion of the wicking element and theheating element.

In some implementations, the heating portion is folded between theheating portion and the at least two legs to isolate the heating portionfrom the at least two legs. In some implementations, the heating portionfurther includes at least one tab that extends from a side of the atleast two tines to allow for easier entry of the wicking element to theinterior volume of the heating portion. In some implementations, the atleast one tab extends away from the interior volume at an angle.

In some implementations, the at least two legs includes a capillaryfeature. The capillary feature may cause an abrupt change in capillarypressure to thereby prevent the vaporizable material from flowing beyondthe capillary feature. In some implementations, the capillary featurecomprises one or more bends in the at least two legs. In someimplementations, the at least two legs extend at an angle towards theinterior volume of the heating portion, the angled at least two legsdefining the capillary feature.

In some implementations, a vaporizer device includes a reservoircontaining vaporizable material, a wicking element in fluidcommunication with the reservoir, and a heating element. The heatingelement includes a heating portion and at least two legs. The heatingportion may include at least two tines spaced apart from one another.The heating portion may be preformed to define an interior volumeconfigured to receive the wicking element such that the heating portionsecures at least a portion of the wicking element to the heatingelement. The heating portion may be configured to contact at least twoseparate surfaces of the wicking element. At least two legs may becoupled to the at least two tines and spaced apart from the heatingportion. The at least two legs may be configured to electricallycommunicate with a power source. Power is configured to be supplied tothe heating portion from the power source to generate heat, therebyvaporizing the vaporizable material stored within the wicking element.

A method of forming an atomizer assembly for a vaporizer device mayinclude securing a wicking element to an interior volume of a heatingelement. The heating element may include a heating portion comprising atleast two tines spaced apart from one another, and at least two legsspaced from the heating portion. The legs may be configured toelectrically communicate with a power source of the vaporizer device.The heating portion is configured to contact at least two surfaces ofthe wicking element. The method may also include coupling the heatingelement to a wick housing configured to surround at least a portion ofthe wicking element and the heating element. The securing may alsoinclude sliding the wicking element into the interior volume of theheating element.

In some implementations, a vaporizer device includes a heating portioncomprising one or more heater traces integrally formed and spaced apartfrom one another, the one or more heater traces configured to contact atleast a portion of a wicking element of the vaporizer device, aconnecting portion configured to receive power from a power source anddirect the power to the heating portion, and a plating layer having aplating material that is different from a material of the heatingportion. The plating layer may be configured to reduce contactresistance between the heating element and the power source, therebylocalizing heating of the heating element to the heating portion.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, show certain aspects of the subject matterdisclosed herein and, together with the description, help explain someof the principles associated with the disclosed implementations. In thedrawings:

FIG. 1A shows a block diagram of a vaporizer consistent withimplementations of the current subject matter;

FIG. 1B illustrates a top view of an embodiment of the vaporizer of FIG.1A, showing a cartridge separated from a vaporizer body;

FIG. 1C illustrates a top view of an embodiment of the vaporizer of FIG.1A, showing the cartridge coupled to the vaporizer body;

FIG. 1D illustrates a perspective exploded view of an embodiment of acartridge, consistent with implementations of the current subjectmatter;

FIG. 1E illustrates a top perspective view of an embodiment of acartridge consistent with implementations of the current subject matter;

FIG. 1F illustrates a bottom perspective view of an embodiment of acartridge consistent with implementations of the current subject matter;

FIG. 2 shows a schematic view of a heating element for use in avaporizer device consistent with implementations of the current subjectmatter;

FIG. 3 shows a schematic view of a heating element for use in avaporizer device consistent with implementations of the current subjectmatter;

FIG. 4 shows a schematic view of a heating element for use in avaporizer device consistent with implementations of the current subjectmatter;

FIG. 5 shows a schematic view of a heating element positioned in avaporizer cartridge for use in a vaporizer device consistent withimplementations of the current subject matter;

FIG. 6 shows a heating element and a wicking element consistent withimplementations of the current subject matter;

FIG. 7 shows a heating element and a wicking element consistent withimplementations of the current subject matter;

FIG. 8 shows a heating element and a wicking element positioned within avaporizer cartridge consistent with implementations of the currentsubject matter;

FIG. 9 shows a heating element and a wicking element positioned within avaporizer cartridge consistent with implementations of the currentsubject matter;

FIG. 10 shows a heating element positioned within a vaporizer cartridgeconsistent with implementations of the current subject matter;

FIG. 11 shows a heating element in an unbent position consistent withimplementations of the current subject matter;

FIG. 12 shows a heating element in a bent position consistent withimplementations of the current subject matter;

FIG. 13 shows a heating element in a bent position consistent withimplementations of the current subject matter;

FIG. 14 shows a heating element in an unbent position consistent withimplementations of the current subject matter;

FIG. 15 shows a heating element in a partially bent position consistentwith implementations of the current subject matter;

FIG. 16 shows a heating element in a partially bent position consistentwith implementations of the current subject matter;

FIG. 17 shows a heating element in a partially bent position consistentwith implementations of the current subject matter;

FIG. 18 shows a heating element in a partially bent position consistentwith implementations of the current subject matter;

FIG. 19 shows a heating element in a partially bent position consistentwith implementations of the current subject matter;

FIG. 20 shows a heating element in an unbent position consistent withimplementations of the current subject matter;

FIG. 21 shows a heating element in a bent position consistent withimplementations of the current subject matter;

FIG. 22 shows a heating element in a partially bent position consistentwith implementations of the current subject matter;

FIG. 23 shows a heating element in a partially bent position consistentwith implementations of the current subject matter;

FIG. 24 shows a heating element in a partially bent position consistentwith implementations of the current subject matter;

FIG. 25 shows a heating element in a partially bent position and awicking element consistent with implementations of the current subjectmatter;

FIG. 26 shows a heating element in a bent position and a wicking elementconsistent with implementations of the current subject matter;

FIG. 27 shows a heating element in a bent position and a wicking elementconsistent with implementations of the current subject matter;

FIG. 28 shows a heating element in an unbent position consistent withimplementations of the current subject matter;

FIG. 29 shows a heating element in an unbent position consistent withimplementations of the current subject matter;

FIG. 30 shows a heating element in an unbent position consistent withimplementations of the current subject matter;

FIG. 31 shows a heating element in an unbent position consistent withimplementations of the current subject matter;

FIG. 32 shows a heating element coupled with a portion of a vaporizercartridge consistent with implementations of the current subject matter;

FIG. 33 shows a heating element and a wicking element positioned withina vaporizer cartridge consistent with implementations of the currentsubject matter;

FIG. 34 shows a heating element in a partially bent position consistentwith implementations of the current subject matter;

FIG. 35 shows a heating element in a partially bent position and awicking element consistent with implementations of the current subjectmatter;

FIG. 36 shows a heating element having a plated portion, in an unbentposition consistent with implementations of the current subject matter;

FIG. 37 shows a heating element having a plated portion, in a bentposition consistent with implementations of the current subject matter;

FIG. 38 shows a heating element having a plated portion positionedwithin a vaporizer cartridge consistent with implementations of thecurrent subject matter;

FIG. 39 shows a perspective view of a heating element in a bent positionconsistent with implementations of the current subject matter;

FIG. 40 shows a side view of a heating element in a bent positionconsistent with implementations of the current subject matter;

FIG. 41 shows a front view of a heating element in a bent positionconsistent with implementations of the current subject matter;

FIG. 42 shows a perspective view of a heating element in a bent positionand a wicking element consistent with implementations of the currentsubject matter;

FIG. 43 shows a heating element positioned within a vaporizer cartridgeconsistent with implementations of the current subject matter;

FIG. 44 shows a perspective view of a heating element in a bent positionconsistent with implementations of the current subject matter;

FIG. 45 shows a side view of a heating element in a bent positionconsistent with implementations of the current subject matter;

FIG. 46 shows a top view of a heating element in a bent positionconsistent with implementations of the current subject matter;

FIG. 47 shows a front view of a heating element in a bent positionconsistent with implementations of the current subject matter;

FIG. 48 shows a perspective view of a heating element in an unbentposition consistent with implementations of the current subject matter;

FIG. 49 shows a top view of a heating element in an unbent positionconsistent with implementations of the current subject matter;

FIG. 50A shows a perspective view of a heating element in a bentposition consistent with implementations of the current subject matter;

FIG. 50B shows a perspective view of a heating element in a bentposition consistent with implementations of the current subject matter;

FIG. 51 shows a side view of a heating element in a bent positionconsistent with implementations of the current subject matter;

FIG. 52 shows a top view of a heating element in a bent positionconsistent with implementations of the current subject matter;

FIG. 53 shows a front view of a heating element in a bent positionconsistent with implementations of the current subject matter;

FIG. 54A shows a perspective view of a heating element in an unbentposition consistent with implementations of the current subject matter;

FIG. 54B shows a perspective view of a heating element in an unbentposition consistent with implementations of the current subject matter;

FIG. 55A shows a top view of a heating element in an unbent positionconsistent with implementations of the current subject matter;

FIG. 55B shows a top view of a heating element in an unbent positionconsistent with implementations of the current subject matter;

FIG. 56 shows a top perspective view of an atomizer assembly consistentwith implementations of the current subject matter;

FIG. 57 shows a bottom perspective view of an atomizer assemblyconsistent with implementations of the current subject matter;

FIG. 58 shows an exploded perspective view of an atomizer assemblyconsistent with implementations of the current subject matter;

FIG. 59 shows a perspective view of a heat shield consistent withimplementations of the current subject matter;

FIG. 60A shows a side cross-sectional view of an atomizer assemblyconsistent with implementations of the current subject matter;

FIG. 60B shows another side cross-sectional view of an atomizer assemblyconsistent with implementations of the current subject matter;

FIG. 61 schematically shows a heating element consistent withimplementations of the current subject matter;

FIG. 62 shows a perspective view of a heating element in a bent positionconsistent with implementations of the current subject matter;

FIG. 63 shows a side view of a heating element in a bent positionconsistent with implementations of the current subject matter;

FIG. 64 shows a perspective view of a heating element in a bent positionconsistent with implementations of the current subject matter;

FIG. 65 shows a side view of a heating element in a bent positionconsistent with implementations of the current subject matter;

FIG. 66 shows a top view of a substrate material with a heating elementconsistent with implementations of the current subject matter;

FIG. 67 shows a top view of a heating element in an unbent positionconsistent with implementations of the current subject matter;

FIG. 68A shows a top perspective view of an atomizer assembly consistentwith implementations of the current subject matter;

FIG. 68B shows a close-up view of a portion of a wick housing of anatomizer assembly consistent with implementations of the current subjectmatter;

FIG. 69 shows a bottom perspective view of an atomizer assemblyconsistent with implementations of the current subject matter;

FIG. 70 shows an exploded perspective view of an atomizer assemblyconsistent with implementations of the current subject matter;

FIGS. 71A-71C show a process of assembling an atomizer consistent withimplementations of the current subject matter;

FIGS. 72A-72C show a process of assembling an atomizer consistent withimplementations of the current subject matter; and

FIG. 73 shows a process flow chart illustrating features of a method offorming and implementing a heating element consistent withimplementations of the current subject matter.

DETAILED DESCRIPTION

Implementations of the current subject matter include devices relatingto vaporizing of one or more materials for inhalation by a user.Examples of vaporizers consistent with implementations of the currentsubject matter include electronic vaporizers, electronic cigarettes,e-cigarettes, or the like.

The vaporizable material used with a vaporizer may optionally beprovided within a cartridge (e.g., a part of the vaporizer that containsthe vaporizable material in a reservoir or other container and that canbe refillable when empty or disposable in favor of a new cartridgecontaining additional vaporizable material of a same or different type).A vaporizer may be a cartridge-using vaporizer, a cartridge-lessvaporizer, or a multi-use vaporizer capable of use with or without acartridge. For example, a multi-use vaporizer may include a heatingchamber (e.g., an oven) configured to receive a vaporizable materialdirectly in the heating chamber and also to receive a cartridge or otherreplaceable device having a reservoir, a volume, or the like for atleast partially containing a usable amount of vaporizable material. Invarious implementations, a vaporizer may be configured for use withliquid vaporizable material (e.g., a carrier solution in which an activeand/or inactive ingredient(s) are suspended or held in solution or aneat liquid form of the vaporizable material itself) or a solidvaporizable material. Some vaporizers consistent with this disclosuremay be capable of use with both solid and liquid vaporizable material. Asolid vaporizable material may include a plant material that emits somepart of the plant material as the vaporizable material (e.g., such thatsome part of the plant material remains as waste after the vaporizablematerial is emitted for inhalation by a user) or optionally can be asolid form of the vaporizable material itself (e.g., a “wax”) such thatall of the solid material can eventually be vaporized for inhalation. Aliquid vaporizable material can likewise be capable of being completelyvaporized or can include some part of the liquid material that remainsafter all of the material suitable for inhalation has been consumed.

Referring to the block diagram of FIG. 1A, a vaporizer 10 typicallyincludes a power source 8 (such as a battery which may be a rechargeablebattery), and a controller 19 (e.g., a processor, circuitry, etc.capable of executing logic) for controlling delivery of heat to anatomizer 26 (also referred to herein as an “atomizer assembly”) to causea vaporizable material to be converted from a condensed form (e.g., asolid, a liquid, a solution, a suspension, a part of an at leastpartially unprocessed plant material, etc.) to the gas phase. Thecontroller 19 may be part of one or more printed circuit boards (PCBs)consistent with certain implementations of the current subject matter.After conversion of the vaporizable material to the gas phase, anddepending on the type of vaporizer, the physical and chemical propertiesof the vaporizable material, and/or other factors, at least some of thegas-phase vaporizable material may condense to form particulate matterin at least a partial local equilibrium with the gas phase as part of anaerosol, which can form some or all of an inhalable dose provided by thevaporizer 10 for a given puff or draw on the vaporizer. It will beunderstood that the interplay between gas and condensed phases in anaerosol generated by a vaporizer can be complex and dynamic, as factorssuch as ambient temperature, relative humidity, chemistry, flowconditions in airflow paths (both inside the vaporizer and in theairways of a human or other animal), mixing of the gas-phase oraerosol-phase vaporizable material with other air streams, etc., mayaffect one or more physical parameters of an aerosol. In somevaporizers, and particularly for vaporizers for delivery of morevolatile vaporizable materials, the inhalable dose may existpredominantly in the gas phase (i.e., formation of condensed phaseparticles may be very limited). In other examples, the converse may betrue.

Vaporizers for use with liquid vaporizable materials (e.g., neatliquids, suspensions, solutions, mixtures, etc.) typically include anatomizer 26 in which a wicking element (also referred to herein as awick (not shown in FIG. 1A), which can include any component (e.g., afibrous wick, a sintered material, a structure having a narrow gap orchannel between surfaces wettable by a liquid vaporizable material)capable of drawing liquid from a reservoir or fluid storage componentunder capillary pressure), conveys an amount of a liquid vaporizablematerial to a part of the atomizer that includes a heating element (alsonot shown in FIG. 1A). The wicking element is generally configured todraw liquid vaporizable material from a reservoir configured to contain(and that may in use contain) the liquid vaporizable material such thatthe liquid vaporizable material may be vaporized by heat delivered froma heating element. The wicking element may also optionally allow air toenter the reservoir to replace the volume of liquid removed. In otherwords, capillary action pulls liquid vaporizable material into the wickfor vaporization by the heating element (described below), and air may,in some implementations of the current subject matter, return to thereservoir through the wick to at least partially equalize pressure inthe reservoir. However, as vaporizable material is drawn out of thereservoir, the pressure inside the reservoir is reduced, therebycreating a vacuum and acting against the capillary action. This canreduce the effectiveness of the wick to draw the vaporizable materialinto the atomizer, thereby reducing the effectiveness of thevaporization device to vaporize a desired amount of vaporizablematerial, such as when a user takes a puff on the vaporizer device.Furthermore, the vacuum created in the reservoir can ultimately resultin the inability to draw all of the vaporizable material into theatomizer, thereby wasting vaporizable material. As such, improvedvaporization devices and/or vaporization cartridges that improve upon orovercome these issues is desired. Other approaches to allowing air backinto the reservoir to equalize pressure are also within the scope of thecurrent subject matter.

The heating element can be or include one or more of a conductiveheater, a radiative heater, and a convective heater. One type of heatingelement is a resistive heating element, which can be constructed of orat least include a material (e.g., a metal or alloy, for example anickel-chromium alloy, or a non-metallic resistor) configured todissipate electrical power in the form of heat when electrical currentis passed through one or more resistive segments of the heating element.In some implementations of the current subject matter, an atomizer caninclude a heating element that includes a resistive coil or otherheating element wrapped around, positioned within, integrated into abulk shape of, pressed into thermal contact with, or otherwise arrangedto deliver heat to a wicking element to cause a liquid vaporizablematerial drawn by the wicking element from a reservoir to be vaporizedfor subsequent inhalation by a user in a gas and/or a condensed (e.g.,aerosol particles or droplets) phase. Other wicking element, heatingelement, and/or atomizer assembly configurations are also possible, asdiscussed further below. For example, a heating element consistent withimplementations of the current subject matter may desirably be shaped toreceive a wicking element and/or crimped or pressed at least partiallyaround the wicking element. The heating element may be bent such thatthe heating element is configured to secure the wicking element betweenat least two or three portions of the heating element. The heatingelement may be bent to conform to a shape of at least a portion of thewicking element. The heating element may be more easily manufacturablethan typical heating elements. The heating element consistent withimplementations of the current subject matter may also be made of anelectrically conductive metal suitable for resistive heating and in someimplementations, the heating element may include selective plating ofanother material to allow the heating element (and thus, the vaporizablematerial) to be more efficiently heated.

Certain vaporizers may also or alternatively be configured to create aninhalable dose of gas-phase and/or aerosol-phase vaporizable materialvia heating of a non-liquid vaporizable material, such as for example asolid-phase vaporizable material (e.g., a wax or the like) or plantmaterial (e.g., tobacco leaves and/or parts of tobacco leaves)containing the vaporizable material. In such vaporizers, a resistiveheating element may be part of or otherwise incorporated into or inthermal contact with the walls of an oven or other heating chamber intowhich the non-liquid vaporizable material is placed. Alternatively, aresistive heating element or elements may be used to heat air passingthrough or past the non-liquid vaporizable material to cause convectiveheating of the non-liquid vaporizable material. In still other examples,a resistive heating element or elements may be disposed in intimatecontact with plant material such that direct conductive heating of theplant material occurs from within a mass of the plant material (e.g., asopposed to only by conduction inward from walls of an oven).

The heating element may be activated (e.g., a controller, which isoptionally part of a vaporizer body as discussed below, may causecurrent to pass from the power source through a circuit including theresistive heating element, which is optionally part of a vaporizercartridge as discussed below), in association with a user puffing (e.g.,drawing, inhaling, etc.) on a mouthpiece 21 of the vaporizer to causeair to flow from an air inlet, along an airflow path that passes anatomizer (e.g., one or more wicking elements and one or more heatingelements in combination), optionally through one or more condensationareas or chambers, to an air outlet in the mouthpiece. Incoming airpassing along the airflow path passes over, around, through, etc., theatomizer, where gas phase vaporizable material is entrained into theair. As noted above, the entrained gas-phase vaporizable material maycondense as it passes through the remainder of the airflow path suchthat an inhalable dose of the vaporizable material in an aerosol formcan be delivered from the air outlet (e.g., in a mouthpiece 21 forinhalation by a user).

Activation of the heating element may be caused by automatic detectionof the puff based on one or more of signals generated by one or moresensors 29, such as for example a pressure sensor or sensors disposed todetect pressure along the airflow path relative to ambient pressure (oroptionally to measure changes in absolute pressure), one or more motionsensors of the vaporizer, one or more flow sensors of the vaporizer,and/or a capacitive lip sensor of the vaporizer; in response todetection of interaction of a user with one or more input devices 41(e.g., buttons or other tactile control devices of the vaporizer 10),receipt of one or more signals from a computing device in communicationwith the vaporizer; and/or via other approaches for determining that apuff is occurring or imminent.

As alluded to in the previous paragraph, a vaporizer consistent withimplementations of the current subject matter may be configured toconnect (e.g., wirelessly or via a wired connection) to a computingdevice (or optionally two or more devices) in communication with thevaporizer. To this end, the controller 19 may include communicationhardware 49. The controller may also include a memory 43. A computingdevice can be a component of a vaporizer system that also includes thevaporizer 10, and can include its own communication hardware, which canestablish a wireless communication channel with the communicationhardware 49 of the vaporizer 10. For example, a computing device used aspart of a vaporizer system may include a general purpose computingdevice (e.g., a smartphone, a tablet, a personal computer, some otherportable device such as a smartwatch, or the like) that executessoftware to produce a user interface for enabling a user of the deviceto interact with a vaporizer. In other implementations of the currentsubject matter, such a device used as part of a vaporizer system can bea dedicated piece of hardware such as a remote control or other wirelessor wired device having one or more physical or soft (e.g., configurableon a screen or other display device and selectable via user interactionwith a touch-sensitive screen or some other input device like a mouse,pointer, trackball, cursor buttons, or the like) interface controls. Thevaporizer can also include one or more output 37 features or devices forproviding information to the user.

A computing device that is part of a vaporizer system as defined abovecan be used for any of one or more functions, such as controlling dosing(e.g., dose monitoring, dose setting, dose limiting, user tracking,etc.), controlling sessioning (e.g., session monitoring, sessionsetting, session limiting, user tracking, etc.), controlling nicotinedelivery (e.g., switching between nicotine and non-nicotine vaporizablematerial, adjusting an amount of nicotine delivered, etc.), obtaininglocational information (e.g., location of other users,retailer/commercial venue locations, vaping locations, relative orabsolute location of the vaporizer itself, etc.), vaporizerpersonalization (e.g., naming the vaporizer, locking/password protectingthe vaporizer, adjusting one or more parental controls, associating thevaporizer with a user group, registering the vaporizer with amanufacturer or warranty maintenance organization, etc.), engaging insocial activities (e.g., games, social media communications, interactingwith one or more groups, etc.) with other users, or the like. The terms“sessioning”, “session”, “vaporizer session,” or “vapor session,” areused generically to refer to a period devoted to the use of thevaporizer. The period can include a time period, a number of doses, anamount of vaporizable material, and/or the like.

In the example in which a computing device provides signals related toactivation of the resistive heating element, or in other examples ofcoupling of a computing device with a vaporizer for implementation ofvarious control or other functions, the computing device executes one ormore computer instructions sets to provide a user interface andunderlying data handling. In one example, detection by the computingdevice of user interaction with one or more user interface elements cancause the computing device to signal the vaporizer 10 to activate theheating element, either to a full operating temperature for creation ofan inhalable dose of vapor/aerosol or to a lower temperature to beginheating the heating element. Other functions of the vaporizer may becontrolled by interaction of a user with a user interface on a computingdevice in communication with the vaporizer.

The temperature of a resistive heating element of a vaporizer may dependon a number of factors, including a material of the heating element, anamount of electrical power delivered to the resistive heating elementand/or a duty cycle at which the electrical power is delivered,conductive heat transfer to other parts of the electronic vaporizerand/or to the environment, latent heat losses due to vaporization of avaporizable material from the wicking element and/or the atomizer as awhole, and convective heat losses due to airflow (e.g., air movingacross the heating element or the atomizer as a whole when a userinhales on the electronic vaporizer). As noted above, to reliablyactivate the heating element or heat the heating element to a desiredtemperature, a vaporizer may, in some implementations of the currentsubject matter, make use of signals from a pressure sensor to determinewhen a user is inhaling. The pressure sensor can be positioned in theairflow path and/or can be connected (e.g., by a passageway or otherpath) to an airflow path connecting an inlet for air to enter the deviceand an outlet via which the user inhales the resulting vapor and/oraerosol such that the sensor experiences pressure changes concurrentlywith air passing through the vaporizer device from the air inlet to theair outlet. In some implementations of the current subject matter, theheating element may be activated in association with a user's puff, forexample by automatic detection of the puff, for example by the pressuresensor detecting a pressure change in the airflow path. As noted above,the heating element may be entirely and/or selectively plated with oneor more other materials to enhance heating performance of the heatingelement.

Typically, the pressure sensor (and/or any other sensors 29) can bepositioned on or coupled (e.g., electrically or electronicallyconnected, either physically or via a wireless connection) to thecontroller 19 (e.g., a printed circuit board assembly or other type ofcircuit board). To take measurements accurately and maintain durabilityof the vaporizer, it can be beneficial to provide a resilient seal 60 toseparate an airflow path from other parts of the vaporizer. The seal 60,which can be a gasket, may be configured to at least partially surroundthe pressure sensor such that connections of the pressure sensor tointernal circuitry of the vaporizer are separated from a part of thepressure sensor exposed to the airflow path.

In an example of a cartridge-based vaporizer, the seal or gasket 60 mayalso separate parts of one or more electrical connections between avaporizer body 50 and a vaporizer cartridge 52. Such arrangements of agasket or seal 60 in a vaporizer 10 can be helpful in mitigating againstpotentially disruptive impacts on vaporizer components resulting frominteractions with environmental factors such as water in the vapor orliquid phases, other fluids such as the vaporizable material, etc.,and/or to reduce escape of air from the designed airflow path in thevaporizer. Unwanted air, liquid or other fluid passing over and/orcontacting circuitry of the vaporizer can cause various unwantedeffects, such as altered pressure readings, and/or can result in thebuildup of unwanted material, such as moisture, the vaporizablematerial, etc., in parts of the vaporizer where they may result in poorpressure signal, degradation of the pressure sensor or other components,and/or a shorter life of the vaporizer. Leaks in the seal or gasket 60can also result in a user inhaling air that has passed over parts of thevaporizer device containing or constructed of materials that may not bedesirable to be inhaled.

A general class of vaporizers that have recently gained popularityincludes a vaporizer body 50 that includes a controller 19, a powersource 8 (e.g., battery), one or more sensors, charging contacts, agasket or seal 60, and a cartridge receptacle 69 configured to receive avaporizer cartridge 52 for coupling with the vaporizer body 50 throughone or more of a variety of attachment structures. In some examples,vaporizer cartridge 52 includes a reservoir 55 for containing a liquidvaporizable material and a mouthpiece 21 for delivering an inhalabledose to a user. The vaporizer cartridge can include an atomizer 26having a wicking element and a heating element, or alternatively, one orboth of the wicking element and the heating element can be part of thevaporizer body 50. In implementations in which any part of the atomizer26 (e.g., heating element and/or wicking element) is part of thevaporizer body 50, the vaporizer can be configured to supply liquidvaporizable material from a reservoir in the vaporizer cartridge to theatomizer part(s) included in the vaporizer body.

Cartridge-based configurations for vaporizers that generate an inhalabledose of a non-liquid vaporizable material via heating of a non-liquidvaporizable material are also within the scope of the current subjectmatter. For example, a vaporizer cartridge may include a mass of a plantmaterial that is processed and formed to have direct contact with partsof one or more resistive heating elements, and such a vaporizercartridge may be configured to be coupled mechanically and electricallyto a vaporizer body that includes a processor, a power source, andelectrical contacts for connecting to corresponding cartridge contactsfor completing a circuit with the one or more resistive heatingelements.

In vaporizers in which the power source 8 is part of a vaporizer body 50and a heating element is disposed in a vaporizer cartridge 52 configuredto couple with the vaporizer body 50, the vaporizer 10 may includeelectrical connection features (e.g., means for completing a circuit)for completing a circuit that includes the controller (e.g., a printedcircuit board, a microcontroller, or the like), the power source, andthe heating element. These features may include at least two, four, ormore contacts on a bottom, side, internal, external, or other surface ofthe vaporizer cartridge 52 (referred to herein as cartridge contacts 65)and at least two, four, or more contacts disposed near a base of thecartridge receptacle (referred to herein as receptacle contacts 62) ofthe vaporizer 10 such that the cartridge contacts 65 and the receptaclecontacts 62 make electrical connections when the vaporizer cartridge 52is inserted into and coupled with the cartridge receptacle 69.

In some implementations, at least a portion of the cartridge contacts 65may face a direction that is approximately perpendicular to the bottomsurface of the vaporizer cartridge. For example, at least a portion ofthe cartridge contacts 65 may be approximately parallel to sides of thevaporizer cartridge and/or may face outwardly towards lateral sides ofthe vaporizer cartridge. In such configurations, the cartridge contacts65 may either be exposed and accessible external to an outer shell ofthe vaporizer cartridge and/or be positioned within a portion of thevaporizer cartridge, such as within an outer shell of the vaporizercartridge. For example, the cartridge contacts 65 may face an interiorwall of the outer shell of the vaporizer cartridge or another portion ofthe vaporizer cartridge. The receptacle contacts 62 of the vaporizer 10may pass into a portion of the vaporizer cartridge, such as the outershell of the vaporizer cartridge to electrically connect with thecartridge contacts 65 when the vaporizer cartridge 52 is inserted intoand coupled with the cartridge receptacle 69. In some implementation,when the vaporizer cartridge 52 is inserted into and coupled with thecartridge receptacle 69, the receptacle contacts 65 may be positionedbetween a portion of the vaporizer cartridge 52 (e.g., the outer shellof the vaporizer cartridge) and the cartridge contacts 65. Thus, atleast a portion of the vaporizer cartridge 52, such as near a base ofthe vaporizer cartridge 52, may include a female portion that receivesat least a portion of the cartridge receptacle 69 that includes thereceptacle contacts 62 such that the cartridge contacts 65 and thereceptacle contacts 62 mate within at least a portion of the vaporizercartridge 52.

The cartridge contacts 65 and/or the receptacle contacts 62 may includeone or more wiping or brush-type contacts that are configured to cleanthe connection between the contacts 65, 62 and other contacts or powersource. For example, the wiping and/or brush type contacts may includetwo parallel, but offset, bosses that frictionally engage and slideagainst one another in a direction that is parallel or perpendicular tothe insertion direction. The cartridge contacts 65, as explained below,may form a portion of the heating element of the vaporizer cartridge.The circuit completed by these electrical connections between thecartridge contacts 65 and the receptacle contacts 62 can allow deliveryof electrical current to the resistive heating element and may furtherbe used for additional functions, such as for example for measuring aresistance of the resistive heating element for use in determiningand/or controlling a temperature of the resistive heating element basedon a thermal coefficient of resistivity of the resistive heatingelement, for identifying a cartridge based on one or more electricalcharacteristics of a resistive heating element or the other circuitry ofthe vaporizer cartridge, etc.

In some examples of the current subject matter, the cartridge contactsand the receptacle contacts can be configured to electrically connect ineither of at least two orientations. In other words, one or morecircuits necessary for operation of the vaporizer can be completed byinsertion of a vaporizer cartridge 52 in the cartridge receptacle 69 ina first rotational orientation (around an axis along which the end ofthe vaporizer cartridge 52 having the cartridge contacts 65 is insertedinto the cartridge receptacle 69 of the vaporizer body 50 and/or atleast a portion of the cartridge receptacle 69 having the receptaclecontacts 62 is inserted into at least a portion of the vaporizercartridge 52 having the cartridge contacts 65) such that a firstcartridge contact of the cartridge contacts 65 is electrically connectedto a first receptacle contact of the receptacle contacts 62, a secondcartridge contact opposite the first cartridge contact of the cartridgecontacts 65 is electrically connected to a second receptacle contact ofthe receptacle contacts 62, and so on. Furthermore, the one or morecircuits necessary for operation of the vaporizer can be completed byinsertion of a vaporizer cartridge 52 in the cartridge receptacle 69 ina second rotational orientation such that the first cartridge contact iselectrically connected to the second receptacle contact and the secondcartridge contact is electrically connected to the first receptaclecontact. This feature of a vaporizer cartridge 52 being reversiblyinsertable into a cartridge receptacle 69 of the vaporizer body 50 isdescribed further below. For example, the cartridge contacts 65 and thereceptacle contacts 62 may mate, such as face-to-face, or asinterlocking, with one another. In some implementations, the one or morecartridge and/or receptacle contacts 65, 62 can include angled or shapedsurfaces, which are symmetrical, so as to be able to mate with oneanother in any one of two reversible orientations.

In one example of an attachment structure for coupling a vaporizercartridge 52 to a vaporizer body, the vaporizer body 50 includes adetent (e.g., a dimple, protrusion, spring, etc.) protruding inwardlyfrom an inner surface the cartridge receptacle 69. One or more exteriorsurfaces (e.g., surfaces positioned along an exterior of the vaporizercartridge or an externally accessible surface positioned within thevaporizer cartridge) of the vaporizer cartridge 52 can includecorresponding recesses (not shown in FIG. 1A) that can fit, receive,and/or otherwise snap over such detents when an end of the vaporizercartridge 52 is inserted into the cartridge receptacle 69 on thevaporizer body 50. When the vaporizer cartridge 52 and the vaporizerbody 50 are coupled (e.g., by insertion of an end of the vaporizercartridge 52 into the cartridge receptacle 69 of the vaporizer body 50),the detent in the vaporizer body 50 may fit within and/or otherwise beheld within the recesses of the vaporizer cartridge 52 to hold thevaporizer cartridge 52 in place when assembled. Such a detent-recessassembly can provide enough support to hold the vaporizer cartridge 52in place to ensure good contact between the at least two cartridgecontacts 65 and the at least two receptacle contacts 62, while allowingrelease of the vaporizer cartridge 52 from the vaporizer body 50 when auser pulls with reasonable force on the vaporizer cartridge 52 todisengage the vaporizer cartridge 52 from the cartridge receptacle 69.

Further to the discussion above about the electrical connections betweena vaporizer cartridge and a vaporizer body 50 being reversible such thatat least two rotational orientations of the vaporizer cartridge 52 inthe cartridge receptacle 69 are possible, in some vaporizers the shapeof the vaporizer cartridge 52, or at least a shape of the end of thevaporizer cartridge that is configured for insertion into the cartridgereceptacle 69 may have rotational symmetry of at least order two. Inother words, the vaporizer cartridge 52 or at least the insertable endof the vaporizer cartridge 52 may be symmetric upon a rotation of 180°around an axis along which the vaporizer cartridge 52 is inserted intothe cartridge receptacle 69. In such a configuration, the circuitry ofthe vaporizer may support identical operation regardless of whichsymmetrical orientation of the vaporizer cartridge 52 occurs.

In some examples, the vaporizer cartridge 52, or at least an end of thevaporizer cartridge 52 configured for insertion in the cartridgereceptacle 69 may have a non-circular cross-section transverse to theaxis along which the vaporizer cartridge 52 is inserted into thecartridge receptacle 69. For example, the non-circular cross-section maybe approximately rectangular, approximately elliptical (e.g., have anapproximately oval shape), non-rectangular but with two sets of parallelor approximately parallel opposing sides (e.g., having aparallelogram-like shape), or other shapes having rotational symmetry ofat least order two. In this context, approximately having a shapeindicates that a basic likeness to the described shape is apparent, butthat sides of the shape in question need not be completely linear andvertices need not be completely sharp. Rounding of both or either ofedges or vertices of the cross-sectional shape is contemplated in thedescription of any non-circular cross-section referred to herein.

The at least two cartridge contacts 65 and the at least two receptaclecontacts 62 can take various forms. For example, one or both sets ofcontacts may include conductive pins, tabs, posts, receiving holes forpins or posts, or the like. Some types of contacts may include springsor other urging features to cause better physical and electrical contactbetween the contacts on the vaporizer cartridge and the vaporizer body.The electrical contacts may optionally be gold-plated, and/or caninclude other materials.

FIG. 1B illustrates an embodiment of the vaporizer body 50 having acartridge receptacle 69 into which the vaporizer cartridge 52 may bereleasably inserted. FIG. 1B shows a top view of the vaporization device10 illustrating the cartridge being positioned for insertion into thevaporizer body 50. When a user puffs on the vaporization device 10, airmay pass between an outer surface of the vaporizer cartridge 52 and aninner surface of a cartridge receptacle 69 on the vaporizer body 50. Aircan then be drawn into an insertable end 3 of the cartridge, through thevaporization chamber that includes or contains the heating element andwick, and out through an outlet of the mouthpiece 21 for delivery of theinhalable aerosol to a user. The reservoir 55 of the vaporizer cartridge52 may be formed in whole or in part from translucent material such thata level of vaporizable material 2 is visible along the vaporizercartridge 52. FIG. 1C illustrates example features that can be includedin embodiments of the vaporizer device 10 consistent withimplementations of the current subject matter. For example, FIG. 1Cshows a top view of an example of the vaporizer device 10 afterconnecting the vaporizer cartridge 52 to the vaporizer body 50. FIG. 1Dillustrates an exploded view of an embodiment of the vaporizer cartridge52, FIG. 1E illustrates a perspective view of an embodiment of thevaporizer cartridge 52, and FIG. 1F illustrates a bottom perspectiveview of an embodiment of the vaporizer cartridge 52. As shown in FIGS.1D-1F, the vaporizer cartridge 52 includes a housing 7 and an atomizerassembly (or the atomizer) 26.

The atomizer assembly 26 (see FIGS. 56-58) may include a wicking element70, a heating element 100, and a wick housing 98. As explained in moredetail below, at least a portion of the heating element 100 ispositioned between the housing 7 and the wick housing 98 and is exposedto be coupled with a portion of the vaporizer body 50 (e.g.,electrically coupled with the receptacle contacts 62). The wick housing98 may include four sides. For example, the wick housing 98 may includetwo opposing short sides and two opposing long sides. The two opposinglong sides may each include at least one (two or more) recess 87 (seeFIGS. 56, 68A). The recesses 87 may be positioned along the long side ofthe wick housing 98 and adjacent to respective intersections between thelong sides and the short sides of the wick housing 98. The recesses 87may be shaped to releasably couple with a corresponding feature (e.g., aspring) on the vaporizer body 50 to secure the vaporizer cartridge 52 tothe vaporizer body 50 within the cartridge receptacle 69. The recesses87 provides a mechanically stable securement means to couple thevaporizer cartridge 52 to the vaporizer body 50.

In some implementations, the wick housing 98 also includes anidentification chip 95, which may be configured to communicate with acorresponding chip reader located on the vaporizer. The identificationchip 95 may be glued and/or otherwise adhered to the wick housing 98,such as on a short side of the wick housing 98. The wick housing 98 mayadditionally or alternatively include a chip recess 83 (see FIG. 57)that is configured to receive the identification chip 95. The chiprecess 83 may be surrounded by two, four, or more walls. The chip recess83 may be shaped to secure the identification chip 95 to the wickhousing 98.

As noted above, the vaporizer cartridge 52 may generally include areservoir, an air path, and an atomizer 26. In some configurations, theheating element and/or atomizer described in accordance withimplementations of the current subject matter can be implementeddirectly into a vaporizer body and/or may not be removable from thevaporizer body. In some implementations, the vaporizer body may notinclude a removable cartridge.

Various advantages and benefits of the current subject matter may relateto improvements relative to current vaporizer configurations, methods ofmanufacture, and the like. For example, a heating element of a vaporizerdevice consistent with implementations of the current subject matter maydesirably be made (e.g., stamped) from a sheet of material and eithercrimped around at least a portion of a wicking element or bent toprovide a preformed element configured to receive the wicking element(e.g., the wicking element is pushed into the heating element and/or theheating element is held in tension and is pulled over the wickingelement). The heating element may be bent such that the heating elementsecures the wicking element between at least two or three portions ofthe heating element. The heating element may be bent to conform to ashape of at least a portion of the wicking element. Configurations ofthe heating element allows for more consistent and enhanced qualitymanufacturing of the heating element. Consistency of manufacturingquality of the heating element may be especially important during scaledand/or automated manufacturing processes. For example, the heatingelement consistent with implementations of the current subject matterhelps to reduce tolerance issues that may arise during manufacturingprocesses when assembling a heating element having multiple components.

In some implementations, accuracy of measurements taken from the heatingelement (e.g., a resistance, a current, a temperature, etc.) may beimproved due at least in part to the improved consistency inmanufacturability of the heating element having reduced toleranceissues. Greater accuracy in measurements can provide an enhanced userexperience when using the vaporizer device. For example, as mentionedabove, the vaporizer 10 may receive a signal to activate the heatingelement, either to a full operating temperature for creation of aninhalable dose of vapor/aerosol or to a lower temperature to beginheating the heating element. The temperature of the heating element ofthe vaporizer may depend on a number of factors, as noted above, andseveral of these factors can be made more predictable by elimination ofpotential variations in fabrication and assembly of atomizer components.A heating element made (e.g., stamped) from a sheet of material andeither crimped around at least a portion of a wicking element or bent toprovide a preformed element desirably helps to minimize heat losses andhelps to ensure that the heating element behaves predictably to beheated to the appropriate temperature.

Additionally, as noted above, the heating element may be entirely and/orselectively plated with one or more materials to enhance heatingperformance of the heating element. Plating all or a portion of theheating element may help to minimize heat losses. Plating may also helpin concentrating the heated portion of the heating element in the properlocation, providing a more efficiently heated heating element andfurther reducing heat losses. Selective plating may help to direct thecurrent provided to the heating element to the proper location.Selective plating may also help to reduce the amount of plating materialand/or costs associated with manufacturing the heating element.

Once the heating element is formed into the appropriate shape via one ormore processes discussed below, the heating element may be crimpedaround the wicking element and/or bent into the proper position toreceive the wicking element. The wicking element may, in someimplementations, be a fibrous wick, formed as an at least approximatelyflat pad or with other cross-sectional shapes such as circles, ovals,etc. A flat pad can allow for the rate that the vaporizable material isdrawn into the wicking element to be controlled more precisely and/oraccurately. For example, a length, width, and/or thickness can beadjusted for optimal performance. A wicking element forming a flat padmay also provide a greater transfer surface area, which may allow forincreased flow of the vaporizable material from the reservoir into thewicking element for vaporization by the heating element (in other words,larger mass transfer of vaporizable material), and from the wickingelement to air flowing past it. In such configurations, the heatingelement may contact the wicking element in multiple directions (e.g., onat least two sides of the wicking element) to increase efficiency of theprocess of drawing vaporizable material into the wicking element andvaporizing the vaporizable material. The flat pad may also be moreeasily shaped and/or cut, and thus may be more easily assembled with theheating element. In some implementations, as discussed in more detailbelow, the heating element may be configured to contact the wickingelement on only one side of the wicking element.

The wicking element may include one or more rigid or compressiblematerials, such as cotton, silica, ceramic, and/or the like. Relative tosome other materials, a cotton wicking element may allow for anincreased and/or more controllable flow rate of vaporizable materialfrom the reservoir of the vaporizer cartridge into the wicking elementto be vaporized. In some implementations, the wicking element forms anat least approximately flat pad that is configured to contact theheating element and/or be secured between at least two portions of theheating element. For example, the at least approximately flat pad mayhave at least a first pair of opposing sides that are approximatelyparallel to one another. In some implementations, the at leastapproximately flat pad may also have at least a second pair of opposingsides that are approximately parallel to one another, and approximatelyperpendicular to the first pair of opposing sides.

FIGS. 2-5 illustrate schematic views of a heating element 100 consistentwith implementations of the current subject matter. For example, FIG. 2illustrates a schematic view of a heating element 100 in an unfoldedposition. As shown, in the unfolded position, the heating element 100forms a planar heating element. The heating element 100 may be initiallyformed of a substrate material. The substrate material is then cutand/or stamped into the proper shape via various mechanical processes,including but not limited to stamping, laser cutting, photo-etching,chemical etching, and/or the like.

The substrate material may be made of an electrically conductive metalsuitable for resistive heating. In some implementations, the heatingelement 100 includes a nickel-chromium alloy, a nickel alloy, stainlesssteel, and/or the like. As discussed below, the heating element 100 maybe plated with a coating in one or more locations on a surface of thesubstrate material to enhance, limit, or otherwise alter the resistivityof the heating element in the one or more locations of the substratematerial (which can be all or a portion of the heating element 100).

The heating element 100 includes one or more tines 102 (e.g., heatingsegments) located in a heating portion 104, one or more legs orconnecting portions 106 (e.g., one, two, or more) located in atransition region 108, and a cartridge contact 65 located in anelectrical contact region 110 and formed at an end portion of each ofthe one or more legs 106. The tines 102, the legs 106, and the cartridgecontacts 65 may be integrally formed. For example, the tines 102, thelegs 106, and the cartridge contacts 65 form portions of the heatingelement 100 that is stamped and/or cut from the substrate material. Insome implementations, the heating element 100 also includes a heatshield 118 that extends from one or more of the legs 106 and also may beintegrally formed with the tines 102, the legs 106, and the cartridgecontacts 65.

In some implementations, at least a portion of the heating portion 104of the heating element 100 is configured to interface with thevaporizable material drawn into the wicking element from the reservoir55 of the vaporizer cartridge 52. The heating portion 104 of the heatingelement 100 may be shaped, sized, and/or otherwise treated to create adesired resistance. For example, the tines 102 located in the heatingportion 104 may be designed so that the resistance of the tines 102matches the appropriate amount of resistance to influence localizedheating in the heating portion 104 to more efficiently and effectivelyheat the vaporizable material from the wicking element. The tines 102form thin path heating segments or traces in series and/or in parallelto provide the desired amount of resistance.

The tines 102 (e.g., traces) may include various shapes, sizes, andconfigurations. In some configurations, one or more of the tines 102 maybe spaced to allow the vaporizable material to be wicked out of thewicking element and from there, vaporized off side edges of each of thetines 102. The shape, length, width, composition, etc., among otherproperties of the tines 102 may be optimized to maximize the efficiencyof generating an aerosol by vaporizing vaporizable material from withinthe heating portion of the heating element 100 and to maximizeelectrical efficiency. The shape, length, width, composition, etc.,among other properties of the tines 102 may additionally oralternatively be optimized to uniformly distribute heat across thelength of the tines 102 (or a portion of the tines 102, such as at theheating portion 104). For example, the width of the tines 102 may beuniform or variable along a length of the tines 102 to control thetemperature profile across at least the heating portion 104 of theheating element 100. In some examples, the length of the tines 102 maybe controlled to achieve a desired resistance along at least a portionof the heating element 100, such as at the heating portion 104. As shownin FIGS. 2-5, the tines 102 each have the same size and shape. Forexample, the tines 102 include an outer edge 103 that is approximatelyaligned and have a generally rectangular shape, with flat or squaredouter edges 103 (see also FIGS. 6-10, and) or rounded outer edges 103(see FIGS. 11 and 12). In some implementations, one or more of the tines102 may include outer edges 103 that are not aligned and/or may bedifferently sized or shaped (see FIGS. 14-19). In some implementations,the tines 102 may be evenly spaced or have variable spacing betweenadjacent tines 102 (see FIGS. 44-49). The particular geometry of thetines 102 may be desirably selected to produce a particular localizedresistance for heating the heating portion 104, and to maximizeperformance of the heating element 100 to heat the vaporizable materialand generate an aerosol.

The heating element 100 may include portions of wider and/or thickergeometry, and/or differing composition relative to the tines 102. Theseportions may form electrical contact areas and/or more conductive parts,and/or may include features for mounting the heating element 100 withinthe vaporizer cartridge. The legs 106 of the heating element 100 extendfrom an end of each outermost tine 102A. The legs 106 form a portion ofthe heating element 100 that has a width and/or thickness that istypically wider than a width of each of the tines 102. Though, in someimplementations, the legs 106 have a width and/or thickness that is thesame as or narrower than the width of each of the tines 102. The legs106 couple the heating element 100 to the wick housing 98 or anotherportion of the vaporizer cartridge 52, so that the heating element 100is at least partially or fully enclosed by the housing 7. The legs 106provide rigidity to encourage the heating element 100 to be mechanicallystable during and after manufacturing. The legs 106 also connect thecartridge contacts 65 with the tines 102 located in the heating portion104. The legs 106 are shaped and sized to allow the heating element 100to maintain the electrical requirements of the heating portion 104. Asshown in FIG. 5, the legs 106 space the heating portion 104 from an endof the vaporizer cartridge 52 when the heating element 100 is assembledwith the vaporizer cartridge 52. As discussed in more detail below, withrespect to at least FIGS. 39-55 and 60-61, the legs 106 may also includea capillary feature 198, which limits or prevents fluid from flowing outof the heating portion 104 to other portions of the heating element 100.

In some implementations, one or more of the legs 106 includes one ormore locating features 116. The locating features 116 may be used forrelative locating of the heating element 100 or portions thereof duringand/or after assembly by interfacing with other (e.g., adjacent)components of the vaporizer cartridge 52. In some implementations, thelocating features 116 may be used during or after manufacturing toproperly position the substrate material for cutting and/or stamping thesubstrate material to form the heating element 100 or post-processing ofthe heating element 100. The locating features 116 may be sheared offand/or cut off before crimping or otherwise bending the heating element100.

In some implementations, the heating element 100 includes one or moreheat shields 118. The heat shields 118 form a portion of the heatingelement 100 that extends laterally from the legs 106. When folded and/orcrimped, the heat shields 118 are positioned offset in a first directionand/or a second direction opposite the first direction in the same planefrom the tines 102. When the heating element 100 is assembled in thevaporizer cartridge 52, the heat shields 118 are configured to bepositioned between the tines 102 (and the heating portion 104) and thebody (e.g., plastic body) of the vaporizer cartridge 52. The heatshields 118 can help to insulate the heating portion 104 from the bodyof the vaporizer cartridge 52. The heat shields 118 help to minimize theeffects of the heat emanating from the heating portion 104 on the bodyof the vaporizer cartridge 52 to protect the structural integrity of thebody of the vaporizer cartridge 52 and to prevent melting or otherdeformation of the vaporizer cartridge 52. The heat shields 118 may alsohelp to maintain a consistent temperature at the heating portion 104 byretaining heat within the heating portion 104, thereby preventing orlimiting heat losses while vaporization is occurring. In someimplementations, the vaporizer cartridge 52 may also or alternativelyinclude a heat shield 118A that is separate from the heating element 100(see FIG. 59).

As noted above, the heating element 100 includes at least two cartridgecontacts 65 that form an end portion of each of the legs 106. Forexample, as shown in FIGS. 2-5, the cartridge contacts 65 may form theportion of the legs 106 that is folded along a fold line 107. Thecartridge contacts 65 may be folded at an angle of approximately 90degrees relative to the legs 106. In some implementations, the cartridgecontacts 65 may be folded at other angles, such as at an angle ofapproximately 15 degrees, 25 degrees, 35 degrees, 45 degrees, 55degrees, 65 degrees, 75 degrees or other ranges therebetween, relativeto the legs 106. The cartridge contacts 65 may be folded towards or awayfrom the heating portion 104, depending on the implementation. Thecartridge contacts 65 may also be formed on another portion of theheating element 100, such as along a length of at least one of the legs106. The cartridge contacts 65 are configured to be exposed to theenvironment when assembled in the vaporizer cartridge 52 (see FIG. 10).

The cartridge contacts 65 may form conductive pins, tabs, posts,receiving holes, or surfaces for pins or posts, or other contactconfigurations. Some types of cartridge contacts 65 may include springsor other urging features to cause better physical and electrical contactbetween the cartridge contacts 65 on the vaporizer cartridge andreceptacle contacts 62 on the vaporizer body 50. In someimplementations, the cartridge contacts 65 include wiping contacts thatare configured to clean the connection between the cartridge contacts 65and other contacts or power source. For example, the wiping contactswould include two parallel, but offset, bosses that frictionally engageand slide against one another in a direction that is parallel orperpendicular to the insertion direction.

The cartridge contacts 65 are configured to interface with thereceptacle contacts 62 disposed near a base of the cartridge receptacleof the vaporizer 10 such that the cartridge contacts 65 and thereceptacle contacts 62 make electrical connections when the vaporizercartridge 52 is inserted into and coupled with the cartridge receptacle69. The cartridge contacts 65 may electrically communicate with thepower source 8 of the vaporizer device (such as via the receptaclecontacts 62, etc.). The circuit completed by these electricalconnections can allow delivery of electrical current to the resistiveheating element to heat at least a portion of the heating element 100and may further be used for additional functions, such as for examplefor measuring a resistance of the resistive heating element for use indetermining and/or controlling a temperature of the resistive heatingelement based on a thermal coefficient of resistivity of the resistiveheating element, for identifying a cartridge based on one or moreelectrical characteristics of a resistive heating element or the othercircuitry of the vaporizer cartridge, etc. The cartridge contacts 65 maybe treated, as explained in more detail below, to provide improvedelectrical properties (e.g., contact resistance) using, for example,conductive plating, surface treatment, and/or deposited materials.

In some implementations, the heating element 100 may be processedthrough a series of crimping and/or bending operations to shape theheating element 100 into a desired three-dimensional shape. For example,the heating element 100 may be preformed to receive or crimped about awicking element 70 to secure the wicking element between at least twoportions (e.g., approximately parallel portions) of the heating element100 (such as between opposing portions of the heating portion 104). Tocrimp the heating element 100, the heating element 100 may be bent alongfold lines 120 towards one another. Folding the heating element 100along fold lines 120 forms a platform tine portion 124 defined by theregion between the fold lines 120 and side tine portions 126 defined bythe region between the fold lines 120 and the outer edges 103 of thetines 102. The platform tine portion 124 is configured to contact oneend of the wicking element 70. The side tine portions 126 are configuredto contact opposite sides of the wicking element 70. The platform tineportion 124 and the side tine portions 126 form a pocket that is shapedto receive the wicking element 70 and/or conform to the shape of atleast a portion of the wicking element 70. The pocket allows the wickingelement 70 to be secured and retained by the heating element 100 withinthe pocket. The platform tine portion 124 and the side tine portions 126contact the wicking element 70 to provide a multi-dimensional contactbetween the heating element 100 and the wicking element 70.Multi-dimensional contact between the heating element 100 and thewicking element 70 provides for a more efficient and/or faster transferof the vaporizable material from the reservoir 55 of the vaporizercartridge 52 to the heating portion 104 (via the wicking element 70) tobe vaporized.

In some implementations, portions of the legs 106 of the heating element100 may also be bent along fold lines 122 away from one another. Foldingthe portions of the legs 106 of the heating element 100 along fold lines122 away from one another locates the legs 106 at a position spaced awayfrom the heating portion 104 (and tines 102) of the heating element 100in a first and/or second direction opposite the first direction (e.g.,in the same plane). Thus, folding the portions of the legs 106 of theheating element 100 along fold lines 122 away from one another spacesthe heating portion 104 from the body of the vaporizer cartridge 52.FIG. 3 illustrates a schematic of the heating element 100 that has beenfolded along the fold lines 120 and fold lines 122 about the wickingelement 70. As shown in FIG. 3, the wicking element is positioned withinthe pocket formed by folding the heating element 100 along fold lines120 and 122.

In some implementations, the heating element 100 may also be bent alongfold lines 123. For example, the cartridge contacts 65 may be benttowards one another (into and out of the page shown in FIG. 4) along thefold lines 123. The cartridge contacts 65 may be exposed to theenvironment to contact the receptacle contacts, while the remainingportions of the heating element 100 are positioned within the vaporizercartridge 52 (see FIGS. 5 and 10).

In use, when a user puffs on the mouthpiece 21 of the vaporizercartridge 52 when the heating element 100 is assembled into thevaporizer cartridge 52, air flows into the vaporizer cartridge and alongan air path. In association with the user puff, the heating element 100may be activated, e.g., by automatic detection of the puff via apressure sensor, by detection of a pushing of a button by the user, bysignals generated from a motion sensor, a flow sensor, a capacitive lipsensor, and/or another approach capable of detecting that a user istaking or about to be taking a puff or otherwise inhaling to cause airto enter the vaporizer device 10 and travel at least along the air path.Power can be supplied from the vaporizer device to the heating element100 at the cartridge contacts 65, when the heating element 100 isactivated.

When the heating element 100 is activated, a temperature increaseresults due to current flowing through the heating element 100 togenerate heat. The heat is transferred to some amount of the vaporizablematerial through conductive, convective, and/or radiative heat transfersuch that at least a portion of the vaporizable material vaporizes. Theheat transfer can occur to vaporizable material in the reservoir and/orto vaporizable material drawn into the wicking element 70 retained bythe heating element 100. In some implementations, the vaporizablematerial can vaporize along one or more edges of the tines 102, asmentioned above. The air passing into the vaporizer device flows alongthe air path across the heating element 100, stripping away thevaporized vaporizable material from the heating element 100. Thevaporized vaporizable material can be condensed due to cooling, pressurechanges, etc., such that it exits the mouthpiece 21 as an aerosol forinhalation by a user.

As noted above, the heating element 100 may be made of variousmaterials, such as nichrome, stainless steel, or other resistive heatermaterials. Combinations of two or more materials may be included in theheating element 100, and such combinations can include both homogeneousdistributions of the two or more materials throughout the heatingelement or other configurations in which relative amounts of the two ormore materials are spatially heterogeneous. For example, the tines 102may have portions that are more resistive and thereby be designed togrow hotter than other sections of the tines or heating element 100. Insome implementations, at least the tines 102 (such as within the heatingportion 104) may include a material that has high conductivity and heatresistance.

The heating element 100 may be entirely or selectively plated with oneor more materials. Since the heating element 100 is made of a thermallyand/or electrically conductive material, such as stainless steel,nichrome, or other thermally and/or electrically conductive alloy, theheating element 100 may experience electrical or heating losses in thepath between the cartridge contacts 65 and the tines 102 in the heatingportion 104 of the heating element 100. To help to reduce heating and/orelectrical losses, at least a portion of the heating element 100 may beplated with one or more materials to reduce resistance in the electricalpath leading to the heating portion 104. In some implementationsconsistent with the current subject matter, it is beneficial for theheating portion 104 (e.g., the tines 102) to remain unplated, with atleast a portion of the legs 106 and/or cartridge contacts 65 beingplated with a plating material that reduces resistance (e.g., either orboth of bulk and contact resistance) in those portions.

For example, the heating element 100 may include various portions thatare plated with different materials. In another example, the heatingelement 100 may be plated with layered materials. Plating at least aportion of the heating element 100 helps to concentrate current flowingto the heating portion 104 to reduce electrical and/or heat losses inother portions of the heating element 100. In some implementations, itis desirable to maintain a low resistance in the electrical path betweenthe cartridge contacts 65 and the tines 102 of the heating element 100to reduce electrical and/or heat losses in the electrical path and tocompensate for the voltage drop that is concentrated across the heatingportion 104.

In some implementations, the cartridge contacts 65 may be selectivelyplated. Selectively plating the cartridge contacts 65 with certainmaterials may minimize or eliminate contact resistance at the pointwhere the measurements are taken and the electrical contact is madebetween the cartridge contacts 65 and the receptacle contacts. Providinga low resistance at the cartridge contacts 65 can provide more accuratevoltage, current, and/or resistance measurements and readings, which canbe beneficial for accurately determining the current actual temperatureof the heating portion 104 of the heating element 100.

In some implementations, at least a portion of the cartridge contacts 65and/or at least a portion of the legs 106 may be plated with one or moreouter plating materials 150. For example, at least a portion of thecartridge contacts 65 and/or at least a portion of the legs 106 may beplated with at least gold, or another material that provides low contactresistance, such as platinum, palladium, silver, copper, or the like.

In some implementations, in order for the low resistance outer platingmaterial to be secured to the heating element 100, a surface of theheating element 100 may be plated with an adhering plating material. Insuch configurations, the adhering plating material may be deposited ontothe surface of the heating element 100 and the outer plating materialmay be deposited onto the adhering plating material, defining first andsecond plating layers, respectively. The adhering plating materialincludes a material with adhesive properties when the outer platingmaterial is deposited onto the adhering plating material. For example,the adhering plating material may include nickel, zinc, aluminum, iron,alloys thereof, or the like. FIGS. 36-38 illustrate examples of theheating element 100 in which the cartridge contacts 65 have beenselectively plated with the adhering plating material and/or the outerplating material.

In some implementations, the surface of the heating element 100 may beprimed for the outer plating material to be deposited onto the heatingelement 100 using non-plating priming, rather than by plating thesurface of the heating element 100 with the adhering plating material.For example, the surface of the heating element 100 may be primed usingetching rather than by depositing the adhering plating material.

In some implementations, all or a portion of the legs 106 and thecartridge contacts 65 may be plated with the adhering plating materialand/or the outer plating material. In some examples, the cartridgecontacts 65 may include at least a portion that has an outer platingmaterial having a greater thickness relative to the remaining portionsof the cartridge contacts 65 and/or the legs 106 of the heating element100. In some implementations, the cartridge contacts 65 and/or the legs106 may have a greater thickness relative to the tines 102 and/or theheating portion 104.

In some implementations, rather than forming the heating element 100 ofa single substrate material and plating the substrate material, theheating element 100 may be formed of various materials that are coupledtogether (e.g., via laser welding, diffusion processes, etc.). Thematerials of each portion of the heating element 100 that is coupledtogether may be selected to provide a low or no resistance at thecartridge contacts 65 and a high resistance at the tines 102 or heatingportion 104 relative to the other portions of the heating element 100.

In some implementations, the heating element 100 may be electroplatedwith silver ink and/or spray coated with one or more plating materials,such as the adhering plating material and the outer plating material.

As mentioned above, the heating element 100 may include various shapes,sizes, and geometries to more efficiently heat the heating portion 104of the heating element 100 and more efficiently vaporize the vaporizablematerial.

FIGS. 6-10 illustrate an example of a heating element 100 consistentwith implementations of the current subject matter. As shown, theheating element 100 includes the one or more tines 102 located in theheating portion 104, the one or more legs 106 extending from the tines102, the cartridge contacts 65 formed at the end portion of each of theone or more legs 106, and the heat shields 118 extending from the one ormore legs 106. In this example, each of the tines 102 have the same orsimilar shape and size. The tines 102 have a squared and/or flat outeredge 103. In FIGS. 6-9, the tines 102 have been crimped about a wickingelement 70 (e.g., a flat pad) to secure the wicking element 70 withinthe pocket of the tines 102.

FIGS. 11-12 illustrate another example of a heating element 100consistent with implementations of the current subject matter in anunbent position (FIG. 11) and a bent position (FIG. 12). As shown, theheating element 100 includes the one or more tines 102 located in theheating portion 104, the one or more legs 106 extending from the tines102, the cartridge contacts 65 formed at the end portion of each of theone or more legs 106, and the heat shields 118 extending from the one ormore legs 106. In this example, each of the tines 102 have the same orsimilar shape and size and the tines 102 have a rounded and/orsemi-circular outer edge 103.

FIG. 13 illustrates another example of a heating element 100 in a bentposition consistent with implementations of the current subject matterthat is similar to the example heating element 100 shown in FIGS. 11-12,but in this example, each of the tines 102 have the same or similarshape and size and the tines 102 have a squared and/or flat outer edge103.

FIGS. 14-19 illustrate other examples of the heating element 100 inwhich at least one of the tines 102 has a size, shape, or position thatis different from the remaining tines 102. For example, as shown inFIGS. 14-15, the heating element 100 includes the one or more tines 102located in the heating portion 104, the one or more legs 106 extendingfrom the tines 102, and the cartridge contacts 65 formed at the endportion of each of the one or more legs 106. In this example, the tines102 include a first set of tines 105A and a second set of tines 105B.The first and second sets of tines 105A, 105B are offset from oneanother. For example, the outer edges 103 of the first and second setsof tines 105A, 105B are not aligned with one another. As shown in FIG.15, when the heating portion 104 is in the bent position, the first setof tines 105A appear to be shorter than the second set of tines 105B inthe first portion of the heating element 100, and the first set of tines105A appear to be longer than the second set of tines 105B in the secondportion of the heating element 100.

As shown in FIGS. 16-17, the heating element 100 includes the one ormore tines 102 located in the heating portion 104, the one or more legs106 extending from the tines 102, and the cartridge contacts 65 formedat the end portion of each of the one or more legs 106. In this example,the tines 102 include a first set of tines 109A and a second set oftines 109B. The first and second sets of tines 109A, 109B are offsetfrom one another. For example, the outer edges 103 of the first andsecond sets of tines 109A, 109B are not aligned with one another. Here,the second set of tines 109B includes a single outermost tine 102A. Asshown in FIGS. 16-17, when the heating portion 104 is in the bentposition, the first set of tines 109A appear to be longer than thesecond set of tines 109B. In addition, in FIGS. 16-17, the tines 102 arenot bent. Rather, the tines 102 are located on a first portion and asecond portion of the heating element 100 that is positionedapproximately parallel to and opposite the first portion. The first setof tines positioned on the first portion of the heating element 100 areseparated from the second set of tines positioned on the second portionof the heating element 100 by a platform portion 130 that is positionedbetween and spaced from both of the first and second set of tines. Theplatform portion 130 is configured to contact an end of the wickingelement 70. The platform portion 130 includes a cutout portion 132. Thecutout portion 132 may provide additional edges along which thevaporizable material can vaporize from when the heating element 100 isactivated.

As shown in FIGS. 18-19, the heating element 100 includes the one ormore tines 102 located in the heating portion 104, the one or more legs106 extending from the tines 102, and the cartridge contacts 65 formedat the end portion of each of the one or more legs 106. In this example,the tines 102 include a first set of tines 109A and a second set oftines 109B. The first and second sets of tines 109A, 109B are offsetfrom one another. For example, the outer edges 103 of the first andsecond sets of tines 109A, 109B are not aligned with one another. Here,each of the first and the second set of tines 109A, 109B includes twotines 102. As shown in FIGS. 18-19, when the heating portion 104 is inthe bent position, the first set of tines 109A appear to be shorter thanthe second set of tines 109B. In addition, in FIGS. 18-19, the tines 102are not bent. Rather, the tines 102 are located on a first portion and asecond portion (that is parallel and opposite the first portion) of theheating element 100. The first set of tines positioned on the firstportion are separated from the second set of tines positioned on thesecond portion by a platform portion that is positioned between andspaced from both of the first and second set of tines. The platformportion is configured to contact an end of the wicking element 70. Theplatform portion includes a cutout portion. The cutout portion mayprovide additional edges along which the vaporizable material canvaporize from when the heating element 100 is activated.

FIGS. 20-25 illustrate another example of a heating element 100consistent with implementations of the current subject matter in anunbent position (FIG. 20) and a bent position (FIGS. 21-25). As shown,the heating element 100 includes the one or more tines 102 located inthe heating portion 104, the one or more legs 106 extending from thetines 102, the cartridge contacts 65 formed at the end portion of eachof the one or more legs 106, and the heat shields 118 extending from theone or more legs 106. In this example, the heating element 100 isconfigured to be crimped around and/or bent to receive acylindrical-shaped wicking element 70 or a wicking element 70 having acircular cross-section. Each of the tines 102 include apertures 140. Theapertures 140 may provide additional edges along which the vaporizablematerial can vaporize from when the heating element 100 is activated.The apertures 140 also reduce the amount of material used to form theheating element 100, reducing the weight of the heating element 100 andthe amount of material used for the heating element 100, therebyreducing material costs.

FIGS. 26-35 illustrate a heating element 100 consistent withimplementations of the current subject matter in which the heatingelement 100 is pressed against one side of the wicking element 70. Asshown, the heating element 100 includes the one or more tines 102located in the heating portion 104, the one or more legs 106 extendingfrom the tines 102, and the cartridge contacts 65 formed at the endportion of each of the one or more legs 106. In these examples, the legs106 and the cartridge contacts 65 are configured to bend in a thirddirection, rather than in a first-second direction that is perpendicularto the third direction. In such a configuration, the tines 102 of theheating portion 104 form a planar platform that faces outwardly from theheating element 100 and is configured to be pressed against the wickingelement 70 (e.g., on one side of the wicking element 70).

FIGS. 28-31 illustrate several examples of the heating element 100consistent with implementations of the current subject matter includingtines 102 configured in various geometries. As mentioned above, thetines 102 form a planar platform that is pressed against one side of thewicking element 70 in use. The legs 106, rather than the tines 102, bendin the bent position.

FIG. 32 illustrates an example of the heating element 100 shown in FIG.28 assembled with a component of the vaporizer cartridge 52, such as awick housing (e.g., the wick housing 98) that houses the wicking element70 and the heating element 100 and FIG. 33 illustrates the heatingelement 100 assembled with an example vaporizer cartridge 52 consistentwith implementations of the current subject matter. As shown thecartridge contacts 65 are bent towards one another in a lateraldirection.

FIGS. 34 and 35 illustrate another example of the heating element 100 inwhich the tines 102 form a platform that is configured to be pressedagainst the wicking element 70. Here, the legs 106 may form spring-likestructures that force the tines 102 to be pressed against the wickingelement 70 when a lateral inward force is applied to each of the legs106. For example, FIG. 35 illustrates an example of the tines 102 beingpressed against the wicking element 70 when power (e.g., a current) issupplied to the heating element 100, such as via the cartridge contacts65.

FIGS. 39-43 illustrate another example of a heating element 100consistent with implementations of the current subject matter. As shown,the heating element 100 includes the one or more tines 102 located inthe heating portion 104, the one or more legs 106 extending from thetines 102, and the cartridge contacts 65 formed at the end portionand/or as part of each of the one or more legs 106. In this example,each of the tines 102 have the same or similar shape and size, and arespaced apart from one another at equal distances. The tines 102 have arounded outer edge 103.

As shown in FIG. 42, the tines 102 have been crimped about a wickingelement 70 (e.g., a flat pad) to secure the wicking element 70 withinthe pocket formed by the tines 102. For example, the tines 102 may befolded and/or crimped to define the pocket in which the wicking element70 resides. The tines 102 include a platform tine portion 124 and sidetine portions 126. The platform tine portion 124 is configured tocontact one side of the wicking element 70 and the side tine portions126 are configured to contact other opposite sides of the wickingelement 70. The platform tine portion 124 and the side tine portions 126form the pocket that is shaped to receive the wicking element 70 and/orconform to the shape of at least a portion of the wicking element 70.The pocket allows the wicking element 70 to be secured and retained bythe heating element 100 within the pocket.

In some implementations, the side tine portions 126 and the platformtine portion 124 retain the wicking element 70 via compression (e.g., atleast a portion of the wicking element 70 is compressed between theopposing side tine portions 126 and/or the platform tine portion 124).The platform tine portion 124 and the side tine portions 126 contact thewicking element 70 to provide a multi-dimensional contact between theheating element 100 and the wicking element 70. Multi-dimensionalcontact between the heating element 100 and the wicking element 70provides for a more efficient and/or faster transfer of the vaporizablematerial from the reservoir 55 of the vaporizer cartridge 52 to theheating portion 104 (via the wicking element 70) to be vaporized.

The one or more legs 106 of the example heating element 100 shown inFIGS. 39-43 includes four legs 106. Each of the legs 106 may includeand/or define a cartridge contact 65 that is configured to contact acorresponding receptacle contact 62 of the vaporizer 10. In someimplementations, each pair of legs 106 (and the cartridge contacts 65)may contact a single receptacle contact 62. The legs 106 may bespring-loaded to allow the legs 106 to maintain contact with thereceptacle contacts 62. The legs 106 may include a portion that extendsalong a length of the legs 106 that is curved to help to maintaincontact with the receptacle contacts 62. Spring-loading the legs 106and/or the curvature of the legs 106 may help to increase and/ormaintain consistent pressure between the legs 106 and the receptaclecontacts 62. In some implementations, the legs 106 are coupled with asupport 97 that helps to increase and/or maintain consistent pressurebetween the legs 106 and the receptacle contacts 62. The support 97 mayinclude plastic, rubber, or other materials to help maintain contactbetween the legs 106 and the receptacle contacts 62. In someimplementations, the support 97 is formed as a part of the legs 106.

The legs 106 may contact one or more wiping contacts that are configuredto clean the connection between the cartridge contacts 65 and othercontacts or power source. For example, the wiping contacts would includeat least two parallel, but offset, bosses that frictionally engage andslide against one another in a direction that is parallel orperpendicular to the insertion direction.

As shown in FIGS. 39-55, the one or more legs 106 of the heating element100 includes four legs 106. FIGS. 48-49, 54A-55B, and 66-67 showexamples of the heating element 100 in the unbent position. As shown,the heating element 100 has an H-shape, defined by the four legs 106 andthe tines 102. This configuration allows for resistance across theheater to be measured more accurately, and reduces variability in theresistance measurements, thereby allowing for more efficiency aerosolgeneration and higher quality aerosol generation. The heating element100 includes two pairs of opposing legs 106. The tines 102 are coupled(e.g., intersect) with each of the pairs of opposing legs 106 at or neara center of each of the pairs of opposing legs 106. The heating portion104 is positioned between the pairs of opposing legs 106.

FIG. 66 illustrates an example of the heating element 100 before theheating element 100 has been stamped and/or otherwise formed from asubstrate material 177. Excess substrate material 177A may be coupledwith the heating element 100 at one, two, or more coupling locations177B. For example, as shown, the excess substrate material 177A may becoupled with the heating element 100 at two coupling locations 177B,near opposing lateral ends 173 of the platform portion of the heatingelement and/or heating portion 104 of the heating element 100. In someimplementations, the heating element 100 may be first be stamped fromthe substrate material 177, and then removed from the excess substratematerial 177A at the coupling locations 177B (e.g., by twisting,pulling, stamping, cutting, etc., the heating element 100).

As noted above, to crimp the heating element 100, the heating element100 may be bent or otherwise folded along fold lines 123, 122A, 122B,120 towards or away from one another (see, for example, FIG. 55A).Though the fold lines are illustrated in FIG. 55A, the example heatingelements 100 described and shown in FIGS. 1D-72C may also be crimped,folded, or otherwise bent along the fold lines. Folding the heatingelement 100 along fold lines 120 forms a platform tine portion 124defined by the region between the fold lines 120 and/or between sidetine portions 126 defined by the region between the fold lines 120 andthe outer edges 103 of the tines 102. The platform tine portion 124 maycontact one end and/or support one end of the wicking element 70. Theside tine portions 126 may contact opposite sides of the wicking element70. The platform tine portion 124 and the side tine portions 126 definean interior volume of the heating element that forms a pocket shaped toreceive the wicking element 70 and/or conform to the shape of at least aportion of the wicking element 70. The interior volume allows thewicking element 70 to be secured and retained by the heating element 100within the pocket. The platform tine portion 124 and the side tineportions 126 contact the wicking element 70 to provide amulti-dimensional contact between the heating element 100 and thewicking element 70. Multi-dimensional contact between the heatingelement 100 and the wicking element 70 provides for a more efficientand/or faster transfer of the vaporizable material from the reservoir 55of the vaporizer cartridge 52 to the heating portion 104 (via thewicking element 70) to be vaporized.

In some implementations, portions of the legs 106 of the heating element100 may also be bent along fold lines 122A, 122B. Folding the portionsof the legs 106 of the heating element 100 along fold lines 122 awayfrom one another locates the legs 106 at a position spaced away from theheating portion 104 (and tines 102) of the heating element 100 in afirst and/or second direction opposite the first direction (e.g., in thesame plane). Thus, folding the portions of the legs 106 of the heatingelement 100 along fold lines 122 away from one another spaces theheating portion 104 from the body of the vaporizer cartridge 52. Foldingthe portions of the legs 106 along the fold lines 122A, 122B forms abridge 185. In some implementations, the bridge 185 helps to reduce oreliminate overflow of vaporizable material from the heating portion 104,such as due to capillary action. The bridge 185 also helps to isolatethe heating portion 104 from the legs 106, so that the heat generated atthe heating portion 104 does not reach the legs 106. This also helps tolocalize heating of the heating element 100 to within the heatingportion 104.

In some implementations, the heating element 100 may also be bent alongfold lines 123 to define the cartridge contacts 65. The cartridgecontacts 65 may be exposed to the environment or may otherwise beaccessible (and may be positioned within an interior of a portion of thecartridge, such as the outer shell) to contact the receptacle contacts,while other portions, such as the heating portion 104 of the heatingelement 100, are positioned within an inaccessible part of the vaporizercartridge 52, such as the wick housing.

In some implementations, the legs 106 include retainer portions 99 thatare configured to be bent around at least a portion of a wick housing 98that surrounds at least a portion of the wicking element 70 and heatingelement 100 (such as the heating portion 104). The retainer portions 99form an end of the legs 106. The retainer portions 99 help to secure theheating element 100 and wicking element 70 to the wick housing 98 (andthe vaporizer cartridge 52). The retainer portions 99 may alternativelybe bent away from at least a portion of the wick housing 98.

FIGS. 44-49 illustrate another example of a heating element 100consistent with implementations of the current subject matter. As shown,the heating element 100 includes the one or more tines 102 located inthe heating portion 104, the one or more legs 106 extending from thetines 102, and the cartridge contacts 65 formed at the end portionand/or as part of each of the one or more legs 106.

The tines 102 may be folded and/or crimped to define the pocket in whicha wicking element 70 (e.g., a flat pad) resides. The tines 102 include aplatform tine portion 124 and side tine portions 126. The platform tineportion 124 is configured to contact one side of the wicking element 70and the side tine portions 126 are configured to contact other oppositesides of the wicking element 70. The platform tine portion 124 and theside tine portions 126 form the pocket that is shaped to receive thewicking element 70 and/or conform to the shape of at least a portion ofthe wicking element 70. The pocket allows the wicking element 70 to besecured and retained by the heating element 100 within the pocket.

In this example, the tines 102 have various shapes and size, and arespaced apart from one another at the same or varying distances. Forexample, as shown, each of the side tine portions 126 includes at leastfour tines 102. In a first pair 170 of adjacent tines 102, each of theadjacent tines 102 is spaced apart at an equal distance from an innerregion 176 positioned near the platform tine portion 124 to an outerregion 178 positioned near the outer edge 103. In a second pair 172 ofadjacent tines 102, the adjacent tines 102 are spaced apart by a varyingdistance from the inner region 176 to the outer region 178. For example,the adjacent tines 102 of the second pair 172 are spaced apart by awidth that is greater at the inner region 176 than at the outer region178. These configurations may help to maintain a constant and uniformtemperature along the length of the tines 102 of the heating portion104. Maintaining a constant temperature along the length of the tines102 may provide higher quality aerosol, as the maximum temperature ismore uniformly maintainable across the entire heating portion 104.

As noted above, each of the legs 106 may include and/or define acartridge contact 65 that is configured to contact a correspondingreceptacle contact 62 of the vaporizer 10. In some implementations, eachpair of legs 106 (and the cartridge contacts 65) may contact a singlereceptacle contact 62. In some implementations, the legs 106 includeretainer portions 99 that are configured to be bent and generally extendaway from the heating portion 104. The retainer portions 99 areconfigured to be positioned within a corresponding recess in the wickhousing 98. The retainer portions 99 form an end of the legs 106. Theretainer portions 99 help to secure the heating element 100 and wickingelement 70 to the wick housing 98 (and the vaporizer cartridge 52). Theretainer portions 99 may have a tip portion 99A that extends from an endof the retainer portion 99 towards the heating portion 104 of theheating element 100. This configuration reduces the likelihood that theretainer portion will contact another portion of the vaporizer cartridge52, or a cleaning device for cleaning the vaporizer cartridge 52.

The outer edge 103 of the tines 102 in the heating portion 104 mayinclude a tab 180. The tab 180 may include one, two, three, four, ormore tabs 180. The tab 180 may extend outwardly from the outer edge 103and extend away from a center of the heating element 100. For example,the tab 180 may be positioned along an edge of the heating element 100surrounding an internal volume defined by at least the side tineportions 126 for receiving the wicking element 70. The tab 180 mayextend outwardly away from the internal volume of the wicking element70. The tab 180 may also extend away in a direction opposite theplatform tine portion 124. In some implementations, tabs 180 positionedon opposing sides of the internal volume of the wicking element 70 mayextend away from one another. This configuration helps to widen theopening leading to the internal volume of the wicking element 70,thereby helping to reduce the likelihood that the wicking element 70will catch, tear, and/or become damaged when assembled with the heatingelement 100. Due to the material of the wicking element 70, the wickingelement 70 may easily catch, tear, and/or otherwise become damaged whenassembled (e.g., positioned within or inserted into) with the heatingelement 100. Contact between the wicking element 70 and the outer edge103 of the tines 102 may also cause damage to the heating element. Theshape and/or positioning of the tab 180 may allow the wicking element 70to more easily be positioned within or into the pocket (e.g., theinternal volume of the heating element 100) formed by the tines 102,thereby preventing or reducing the likelihood that the wicking element70 and/or the heating element will be damaged. Thus, the tabs 180 helpto reduce or prevent damage caused to the heating element 100 and/or thewicking element 70 upon entry of the wicking element 70 into thermalcontact with the heating element 100. The shape of the tab 180 alsohelps to minimize impact on the resistance of the heating portion 104.

In some implementations, at least a portion of the cartridge contacts 65and/or at least a portion of the legs 106 may be plated with one or moreouter plating materials 150 to reduce contact resistance at the pointwhere the heating element 100 contacts the receptacle contacts 62.

FIGS. 50A-55B illustrate another example of a heating element 100consistent with implementations of the current subject matter. As shown,the heating element 100 includes the one or more tines 102 located inthe heating portion 104, the one or more legs 106 extending from thetines 102, and the cartridge contacts 65 formed at the end portionand/or as part of each of the one or more legs 106.

The tines 102 may be folded and/or crimped to define the pocket in whicha wicking element 70 (e.g., flat pad) resides. The tines 102 include aplatform tine portion 124 and side tine portions 126. The platform tineportion 124 is configured to contact one side of the wicking element 70and the side tine portions 126 are configured to contact other oppositesides of the wicking element 70. The platform tine portion 124 and theside tine portions 126 form the pocket that is shaped to receive thewicking element 70 and/or conform to the shape of at least a portion ofthe wicking element 70. The pocket allows the wicking element 70 to besecured and retained by the heating element 100 within the pocket.

In this example, the tines 102 have the same shape and size and arespaced apart from one another at equal distances. Here, the tines 102include a first side tine portion 126A and a second side tine portion126B that are spaced apart by the platform tine portion 124. Each of thefirst and second side tine portions 126A, 126B include an inner region176 positioned near the platform tine portion 124 to an outer region 178positioned near the outer edge 103. At the outer region 178, the firstside tine portion 126A is positioned approximately parallel to thesecond tine portion 126B. At the inner region 176, the first side tineportion 126A is positioned offset from the second tine portion 126B andthe first and second side tine portions 126A, 126B are not parallel.This configuration may help to maintain a constant and uniformtemperature along the length of the tines 102 of the heating portion104. Maintaining a constant temperature along the length of the tines102 may provide higher quality aerosol, as the maximum temperature ismore uniformly maintainable across the entire heating portion 104.

As noted above, each of the legs 106 may include and/or define acartridge contact 65 that is configured to contact a correspondingreceptacle contact 62 of the vaporizer 10. In some implementations, eachpair of legs 106 (and the cartridge contacts 65) may contact a singlereceptacle contact 62. In some implementations, the legs 106 includeretainer portions 99 that are configured to be bent and generally extendaway from the heating portion 104. The retainer portions 99 areconfigured to be positioned within a corresponding recess in the wickhousing 98. The retainer portions 99 form an end of the legs 106. Theretainer portions 99 help to secure the heating element 100 and wickingelement 70 to the wick housing 98 (and the vaporizer cartridge 52). Theretainer portions 99 may have a tip portion 99A that extends from an endof the retainer portion 99 towards the heating portion 104 of theheating element 100. This configuration reduces the likelihood that theretainer portion will contact another portion of the vaporizer cartridge52, or a cleaning device for cleaning the vaporizer cartridge 52.

The outer edge 103 of the tines 102 in the heating portion 104 mayinclude a tab 180. The tab 180 may extend outwardly from the outer edge103 and extend away from a center of the heating element 100. The tab180 may be shaped to allow the wicking element 70 to more easily bepositioned within the pocket formed by the tines 102, thereby preventingor reducing the likelihood that the wicking element 70 will get caughton the outer edge 103. The shape of the tab 180 helps to minimize impacton the resistance of the heating portion 104.

In some implementations, at least a portion of the cartridge contacts 65and/or at least a portion of the legs 106 may be plated with one or moreouter plating materials 150 to reduce contact resistance at the pointwhere the heating element 100 contacts the receptacle contacts 65.

FIGS. 56-57 illustrate an example of the atomizer assembly 26, with theheating element 100 assembled with the wick housing 98, and FIG. 58illustrates an exploded view of the atomizer assembly 26, consistentwith implementations of the current subject matter. The wick housing 98may be made of plastic, polypropylene, and the like. The wick housing 98includes four recesses 192 in which at least a portion of each of thelegs 106 of the heating element 100 may be positioned and secured. Asshown, the wick housing 98 also includes an opening 193 providing accessto an internal volume 194, in which at least the heating portion 104 ofthe heating element 100 and the wicking element 70 are positioned.

The wick housing 98 may also include a separate heat shield 118A, whichis shown in FIG. 59. The heat shield 118A is positioned within theinternal volume 194 within the wick housing 98 between the walls of thewick housing 98 and the heating element 100. The heat shield 118A isshaped to at least partially surround the heating portion 104 of theheating element 100 and to space the heating element 100 from the sidewalls of the wick housing 98. The heat shield 118A can help to insulatethe heating portion 104 from the body of the vaporizer cartridge 52and/or the wick housing 98. The heat shield 118A helps to minimize theeffects of the heat emanating from the heating portion 104 on the bodyof the vaporizer cartridge 52 and/or the wick housing 98 to protect thestructural integrity of the body of the vaporizer cartridge 52 and/orthe wick housing 98 and to prevent melting or other deformation of thevaporizer cartridge 52 and/or the wick housing 98. The heat shield 118Amay also help to maintain a consistent temperature at the heatingportion 104 by retaining heat within the heating portion 104, therebypreventing or limiting heat losses.

The heat shield 118A includes one or more slots 190 (e.g., three slots)at one end that align with one or more slots (e.g., one, two, three,four, five, six, or seven or more slots) 196 formed in a portion of thewick housing 98 opposite the opening 193, such as a base of the wickhousing 98 (see FIGS. 57 and 69). The one or more slots 190, 196 allowfor the escape of pressure caused by the flow of liquid vaporizablematerial within the heater portion 104 and vaporization of vaporizablematerial, without affecting liquid flow of the vaporizable material.

In some implementations, flooding may occur between the heating element100 (e.g., the legs 106) and an outer wall of the wick housing 98 (orbetween portions of the heating element 100). For example, liquidvaporizable material may build up due to capillary pressure between thelegs 106 of the heating element 100 and the outer wall of the wickhousing 98, as indicated by liquid path 199. In such cases, there may besufficient capillary pressure to draw the liquid vaporizable materialout of the reservoir and/or the heating portion 104. To help limitand/or prevent liquid vaporizable material from escaping the internalvolume of the wick housing 98 (or the heating portion 104), the wickhousing 98 and/or the heating element 100 may include a capillaryfeature that causes an abrupt change in capillary pressure, therebyforming a liquid barrier that prevents the liquid vaporizable materialfrom passing the feature without the use of an additional seal (e.g., ahermetic seal). The capillary feature may define a capillary break,formed by a sharp point, a bend, a curved surface, or other surface inthe wick housing 98 and/or the heating element 100. The capillaryfeature allows a conductive element (e.g., the heating element 100) tobe positioned within both a wet and dry region.

The capillary feature may be positioned on and/or form a part of theheating element 100 and/or the wick housing 98 and causes an abruptchange in capillary pressure. For example, the capillary feature mayinclude a bend, sharp point, curved surface, angled surface, or othersurface feature that causes an abrupt change in capillary pressurebetween the heating element and the wick housing, along a length of theheating element, or another component of the vaporizer cartridge. Thecapillary feature may also include a protrusion or other portion of theheating element and/or wick housing that widens a capillary channel,such as a capillary channel formed between portions of the heatingelement, between the heating element and the wick housing, and the like,that is sufficient to reduce the capillary pressure within the capillarychannel (e.g., the capillary feature spaces the heating element from thewick housing) such that the capillary channel does not draw liquid intothe capillary channel. Thus, the capillary feature prevents or limitsliquid from flowing along a liquid path beyond the capillary feature,due at least in part to the abrupt change and/or reduction in capillarypressure. The size and/or shape of the capillary feature (e.g., thebend, sharp point, curved surface, angled surface, protrusion, and thelike) may be a function of a wetting angle formed between materials,such as the heating element and wick housing, or other walls of acapillary channel formed between components, may be a function of amaterial of the heating element and/or the wick housing or othercomponent, and/or may be a function of a size of a gap formed betweentwo components, such as the heating element and/or wick housing definingthe capillary channel, among other properties.

As an example, FIGS. 60A and 60B illustrate the wick housing 98 having acapillary feature 198 that causes an abrupt change in capillarypressure. The capillary feature 198 prevents or limits liquid fromflowing along the liquid path 199 beyond the capillary feature 198, andhelps to prevent liquid from pooling between the legs 106 and the wickhousing 98. The capillary feature 198 on the wick housing 98 spaces theheating element 100 (e.g., a component made of metal, etc.) away fromthe wick housing 98 (e.g., a component made of plastic, etc.), therebyreducing the capillary strength between the two components. Thecapillary feature 198 shown in FIGS. 60A and 60B also includes a sharpedge at an end of an angled surface of the wick housing that limits orprevents liquid from flowing beyond the capillary feature 198.

As shown in FIG. 60B, the legs 106 of the heating element 100 may alsobe angled inwardly towards the interior volume of the heating element100 and/or wick housing 98. The angled legs 106 may form a capillaryfeature that helps to limit or prevent liquid from flowing over an outersurface of the heating element and along the legs 106 of the heatingelement 100.

As another example, the heating element 100 may include a capillaryfeature (e.g., a bridge 185) that is formed with the one or more legs106 and spaces the legs 106 away from the heating portion 104 (See FIGS.39-55). The bridge 185 may be formed by folding the heating element 100along the fold lines 120, 122. In some implementations, the bridge 185helps to reduce or eliminate overflow of vaporizable material from theheating portion 104, such as due to capillary action. In some examples,such as the example heating elements 100 shown in FIGS. 50A-55B, thebridge 185 is angled and/or includes a bend to help limit fluid flow outof the heating portion 104.

As another example, the heating element 100 may include a capillaryfeature 198 that defines a sharp point to causes an abrupt change incapillary pressure, thereby preventing liquid vaporizable material fromflowing beyond the capillary feature 198. FIG. 61 shows an example ofthe heating element 100 having the capillary feature 198, consistentwith implementations of the current subject matter. As shown in FIG. 61,the capillary feature 198 may form an end of the bridge 185 that extendsoutwardly away from the heating portion by a distance that is greaterthan a distance between the legs 106 and the heating portion 104. Theend of the bridge 185 may be a sharp edge to further help prevent liquidvaporizable material from passing to the legs 106 and/or out of theheating portion 104, thereby reducing leaking and increasing the amountof vaporizable material that remains within the heating portion 104.

FIGS. 62-63 illustrate a variation of the heating element 100 shown inFIGS. 44-49. In this variation of the heating element 100, the legs 106of the heating element 100 include a bend at an inflection region 111.The bend in the legs 106 may form a capillary feature 198, which helpsto prevent liquid vaporizable material from flowing beyond the capillaryfeature 198. For example, the bend may create an abrupt change incapillary pressure, which may also help to limit or prevent liquidvaporizable material from flowing beyond the bend and/or from poolingbetween the legs 106 and the wick housing 98, and may help to limit orprevent liquid vaporizable material from flowing out of the heatingportion 104.

FIGS. 64-65 illustrate a variation of the heating elements 100 shown inFIGS. 50A-55B. In this variation of the heating element 100, the legs106 of the heating element 100 include a bend at an inflection region111. The bend in the legs 106 may form a capillary feature 198, whichhelps to prevent liquid vaporizable material from flowing beyond thecapillary feature 198. For example, the bend may create an abrupt changein capillary pressure, which also helps to limit or prevent liquidvaporizable material from flowing beyond the bend and/or from poolingbetween the legs 106 and the wick housing 98, and may help to limit orprevent liquid vaporizable material from flowing out of the heatingportion 104.

FIGS. 68A-69 illustrate another example of the atomizer assembly 26,with the heating element 100 assembled with the wick housing 98 and theheat shield 118A, and FIG. 70 illustrates an exploded view of theatomizer assembly 26, consistent with implementations of the currentsubject matter. The wick housing 98 may be made of plastic,polypropylene, and the like. The wick housing 98 includes four recesses192 in which at least a portion of each of the legs 106 of the heatingelement 100 may be positioned and secured. Within the recesses 192, thewick housing 98 may include one or more wick housing retention features93 (see FIG. 72A) that help to secure the heating element 100 to thewick housing 98, such as, for example, via a snap-fit arrangementbetween at least a portion of the legs 106 of the heating element 100and the wick housing retention features 93. The wick housing retentionfeatures 93 may also help to space the heating element 100 from asurface of the wick housing 98, to help prevent heat from acting on thewick housing and melting a portion of the wick housing 98.

As shown, the wick housing 98 also includes an opening 193 providingaccess to an internal volume 194, in which at least the heating portion104 of the heating element 100 and the wicking element 70 arepositioned.

The wick housing 98 may also include one or more other cutouts that helpto space the heating element 100 from a surface of the wick housing 98to reduce the amount of heat that contacts the surface of the wickhousing 98. For example, the wick housing 98 may include cutouts 91. Thecutouts 91 may be formed along an outer surface of the wick housing 98proximate to the opening 193. The cutouts 91 may also include acapillary feature, such as the capillary feature 198. The capillaryfeature of the cutouts 91 may define a surface (e.g., curved surface198) that breaks tangency points between adjacent (or intersecting)walls (such as the walls of the wick housing). The curved surface 198may have a radius that is sufficient to reduce or eliminate thecapillarity formed between the adjacent outer walls of the wick housing.

Referring to FIGS. 68A-69, the wick housing 98 may include a tab 89. Thetab 89 may help to properly position and/or orient the wick housingduring assembly of the vaporizer cartridge, with respect to one or moreother components of the vaporizer cartridge. For example, added materialforming the tab 89 shifts the center of mass of the wick housing 98. Dueto the shifted center of mass, the wick housing 98 may rotate or slidein a certain orientation to align with a corresponding feature ofanother component of the vaporizer cartridge during assembly.

FIGS. 71A-71C illustrate an example method of forming the atomizerassembly 26 of the vaporizer cartridge 52, including the wick housing98, the wicking element 70, and the heating element 100, consistent withimplementations of the current subject matter. As shown in FIG. 71A, thewicking element 70 may be inserted into the pocket formed in the heatingelement 100 (e.g., formed by the side tine portions 126 and the platformtine portion 124. In some implementations, the wicking element 70expands after being secured to the heating element 100, when vaporizablematerial is introduced to the wicking element 70.

FIG. 71B shows the wicking element 70 and the heating element 100 beingcoupled to the wick housing 98 and FIG. 71C shows an example of thewicking element 70 and the heating element 100 assembled with the wickhousing 98. At least a portion of the heating element 100, such as theheating portion 104 may be positioned within the internal volume of thewick housing 98. The legs 106 (e.g., the retainer portions 99) of theheating element 100 may couple with the outer walls of the wick housing98 via, for example, a snap-fit arrangement. In particular, the retainerportions 99 of the legs 106 may couple with and be positioned at leastpartially within the recesses in the wick housing 98.

FIGS. 72A-72C illustrate another example method of forming the atomizerassembly 26 of the vaporizer cartridge 52, including the wick housing98, the wicking element 70, and the heating element 100, consistent withimplementations of the current subject matter. As shown in FIG. 72A, theheating element 100 may be coupled to the wick housing 98, for example,by inserting or otherwise positioning the at least a portion of theheating element 100, such as the heating portion 104 within the internalvolume of the wick housing 98. The legs 106 (e.g., the retainer portions99) of the heating element 100 may couple with the outer walls of thewick housing 98 via, for example, a snap-fit arrangement. In particular,the retainer portions 99 or another portion of the legs 106 may couplewith and be positioned at least partially within the recesses in thewick housing 98, for example, by coupling with the wick housingretention features 93.

As shown in FIG. 72B, the wicking element 70 may be inserted into thepocket formed in the heating element 100 (e.g., formed by the side tineportions 126 and the platform tine portion 124. In some implementations,the wicking element 70 is compressed as the wicking element 70 iscoupled with the heating element 70. In some implementations, thewicking element 70 fits within the heating element 70 and expands afterbeing secured to the heating element 100, when vaporizable material isintroduced to the wicking element 70.

FIG. 72C shows an example of the wicking element 70 and the heatingelement 100 assembled with the wick housing 98 to form the atomizerassembly 26.

FIG. 73 illustrates an example process 3600 for assembling the heatingelement 100 consistent with implementations of the current subjectmatter. The process flow chart 3600 illustrates features of a method,which may optionally include some or all of the following. At block3610, a planar substrate having resistive heating properties isprovided. At block 3612, the planar substrate may be cut and/or stampedinto the desired geometry. At block 3614, at least a portion of theheating element 100 may be plated. For example, as mentioned above, oneor more layers of a plating material (e.g., an adhering plating materialand/or an outer plating material) may be deposited onto at least aportion of an outer surface of the heating element 100. At block 3616,the heating portion 104 (e.g., the tines 102) may be bent and/orotherwise crimped about a wicking element to match the shape of thewicking element and to secure the wicking element to the heatingelement. At block 3618, the cartridge contacts 65, which in someimplementations form an end portion of the legs 106 of the heatingelement 100, may be bent in a first or second direction along a plane ora third direction that is perpendicular to the first or seconddirection. At block 3620, the heating element 100 may be assembled intoa vaporizer cartridge 52 and fluid communication between the wickingelement 70 and a reservoir of vaporizable material may be caused. At3622, the vaporizable material may be drawn into the wicking element 70,which may be positioned in contact with at least two surfaces of theheating portion 104 of the heating element 100. At block 3624, a heatingmeans may be provided to the cartridge contacts 65 of the heatingelement to heat the heating element 100 at least the heating portion104. The heating causes vaporization of the vaporizable material. Atblock 3626, the vaporized vaporizable material is entrained in a flow ofair to a mouthpiece of the vaporization cartridge in which the heatingelement is positioned.

Terminology

When a feature or element is herein referred to as being “on” anotherfeature or element, it can be directly on the other feature or elementor intervening features and/or elements may also be present. Incontrast, when a feature or element is referred to as being “directlyon” another feature or element, there are no intervening features orelements present. It will also be understood that, when a feature orelement is referred to as being “connected”, “attached” or “coupled” toanother feature or element, it can be directly connected, attached orcoupled to the other feature or element or intervening features orelements may be present. In contrast, when a feature or element isreferred to as being “directly connected”, “directly attached” or“directly coupled” to another feature or element, there are nointervening features or elements present.

Although described or shown with respect to one embodiment, the featuresand elements so described or shown can apply to other embodiments. Itwill also be appreciated by those of skill in the art that references toa structure or feature that is disposed “adjacent” another feature mayhave portions that overlap or underlie the adjacent feature.

Terminology used herein is for the purpose of describing particularembodiments and implementations only and is not intended to be limiting.For example, as used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification,specify the presence of stated features, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, steps, operations, elements, components, and/orgroups thereof. As used herein, the term “and/or” includes any and allcombinations of one or more of the associated listed items and may beabbreviated as “/”.

In the descriptions above and in the claims, phrases such as “at leastone of” or “one or more of” may occur followed by a conjunctive list ofelements or features. The term “and/or” may also occur in a list of twoor more elements or features. Unless otherwise implicitly or explicitlycontradicted by the context in which it used, such a phrase is intendedto mean any of the listed elements or features individually or any ofthe recited elements or features in combination with any of the otherrecited elements or features. For example, the phrases “at least one ofA and B;” “one or more of A and B;” and “A and/or B” are each intendedto mean “A alone, B alone, or A and B together.” A similarinterpretation is also intended for lists including three or more items.For example, the phrases “at least one of A, B, and C;” “one or more ofA, B, and C;” and “A, B, and/or C” are each intended to mean “A alone, Balone, C alone, A and B together, A and C together, B and C together, orA and B and C together.” Use of the term “based on,” above and in theclaims is intended to mean, “based at least in part on,” such that anunrecited feature or element is also permissible.

Spatially relative terms, such as “forward”, “rearward”, “under”,“below”, “lower”, “over”, “upper” and the like, may be used herein forease of description to describe one element or feature's relationship toanother element(s) or feature(s) as illustrated in the figures. It willbe understood that the spatially relative terms are intended toencompass different orientations of the device in use or operation inaddition to the orientation depicted in the figures. For example, if adevice in the figures is inverted, elements described as “under” or“beneath” other elements or features would then be oriented “over” theother elements or features. Thus, the exemplary term “under” canencompass both an orientation of over and under. The device may beotherwise oriented (rotated 90 degrees or at other orientations) and thespatially relative descriptors used herein interpreted accordingly.Similarly, the terms “upwardly”, “downwardly”, “vertical”, “horizontal”and the like are used herein for the purpose of explanation only unlessspecifically indicated otherwise.

Although the terms “first” and “second” may be used herein to describevarious features/elements (including steps), these features/elementsshould not be limited by these terms, unless the context indicatesotherwise. These terms may be used to distinguish one feature/elementfrom another feature/element. Thus, a first feature/element discussedbelow could be termed a second feature/element, and similarly, a secondfeature/element discussed below could be termed a first feature/elementwithout departing from the teachings provided herein.

As used herein in the specification and claims, including as used in theexamples and unless otherwise expressly specified, all numbers may beread as if prefaced by the word “about” or “approximately,” even if theterm does not expressly appear. The phrase “about” or “approximately”may be used when describing magnitude and/or position to indicate thatthe value and/or position described is within a reasonable expectedrange of values and/or positions. For example, a numeric value may havea value that is +/−0.1% of the stated value (or range of values), +/−1%of the stated value (or range of values), +/−2% of the stated value (orrange of values), +/−5% of the stated value (or range of values), +/−10%of the stated value (or range of values), etc. Any numerical valuesgiven herein should also be understood to include about or approximatelythat value, unless the context indicates otherwise. For example, if thevalue “10” is disclosed, then “about 10” is also disclosed. Anynumerical range recited herein is intended to include all sub-rangessubsumed therein. It is also understood that when a value is disclosedthat “less than or equal to” the value, “greater than or equal to thevalue” and possible ranges between values are also disclosed, asappropriately understood by the skilled artisan. For example, if thevalue “X” is disclosed the “less than or equal to X” as well as “greaterthan or equal to X” (e.g., where X is a numerical value) is alsodisclosed. It is also understood that the throughout the application,data is provided in a number of different formats, and that this data,represents endpoints and starting points, and ranges for any combinationof the data points. For example, if a particular data point “10” and aparticular data point “15” are disclosed, it is understood that greaterthan, greater than or equal to, less than, less than or equal to, andequal to 10 and 15 are considered disclosed as well as between 10 and15. It is also understood that each unit between two particular unitsare also disclosed. For example, if 10 and 15 are disclosed, then 11,12, 13, and 14 are also disclosed.

Although various illustrative embodiments are described above, any of anumber of changes may be made to various embodiments without departingfrom the teachings herein. For example, the order in which variousdescribed method steps are performed may often be changed in alternativeembodiments, and in other alternative embodiments one or more methodsteps may be skipped altogether. Optional features of various device andsystem embodiments may be included in some embodiments and not inothers. Therefore, the foregoing description is provided primarily forexemplary purposes and should not be interpreted to limit the scope ofthe claims.

One or more aspects or features of the subject matter described hereincan be realized in digital electronic circuitry, integrated circuitry,specially designed application specific integrated circuits (ASICs),field programmable gate arrays (FPGAs) computer hardware, firmware,software, and/or combinations thereof. These various aspects or featurescan include implementation in one or more computer programs that areexecutable and/or interpretable on a programmable system including atleast one programmable processor, which can be special or generalpurpose, coupled to receive data and instructions from, and to transmitdata and instructions to, a storage system, at least one input device,and at least one output device. The programmable system or computingsystem may include clients and servers. A client and server aregenerally remote from each other and typically interact through acommunication network. The relationship of client and server arises byvirtue of computer programs running on the respective computers andhaving a client-server relationship to each other.

These computer programs, which can also be referred to programs,software, software applications, applications, components, or code,include machine instructions for a programmable processor, and can beimplemented in a high-level procedural language, an object-orientedprogramming language, a functional programming language, a logicalprogramming language, and/or in assembly/machine language. As usedherein, the term “machine-readable medium” refers to any computerprogram product, apparatus and/or device, such as for example magneticdiscs, optical disks, memory, and Programmable Logic Devices (PLDs),used to provide machine instructions and/or data to a programmableprocessor, including a machine-readable medium that receives machineinstructions as a machine-readable signal. The term “machine-readablesignal” refers to any signal used to provide machine instructions and/ordata to a programmable processor. The machine-readable medium can storesuch machine instructions non-transitorily, such as for example as woulda non-transient solid-state memory or a magnetic hard drive or anyequivalent storage medium. The machine-readable medium can alternativelyor additionally store such machine instructions in a transient manner,such as for example as would a processor cache or other random accessmemory associated with one or more physical processor cores.

The examples and illustrations included herein show, by way ofillustration and not of limitation, specific embodiments in which thesubject matter may be practiced. As mentioned, other embodiments may beutilized and derived there from, such that structural and logicalsubstitutions and changes may be made without departing from the scopeof this disclosure. Such embodiments of the inventive subject matter maybe referred to herein individually or collectively by the term“invention” merely for convenience and without intending to voluntarilylimit the scope of this application to any single invention or inventiveconcept, if more than one is, in fact, disclosed. Thus, althoughspecific embodiments have been illustrated and described herein, anyarrangement calculated to achieve the same purpose may be substitutedfor the specific embodiments shown. This disclosure is intended to coverany and all adaptations or variations of various embodiments.Combinations of the above embodiments, and other embodiments notspecifically described herein, will be apparent to those of skill in theart upon reviewing the above description.

1.-91. (canceled)
 92. An atomizer assembly for a vaporizer cartridge,the vaporizer cartridge configured to be coupled to a vaporizer body ofa vaporizer device, the atomizer assembly comprising: a wick housingcomprising an outer wall at least partially defining an internal volumeconfigured to receive a wicking element and at least a heating portionof a heating element, the heating element also comprising a connectingportion configured to extend out of the internal volume and over theouter wall such that the outer wall is positioned between the heatingportion and the connecting portion, the outer wall comprising twoopposing short sides and two opposing long sides, each of the twoopposing long sides having formed therein a recess configured toreleasably couple the vaporizer cartridge to a corresponding feature ofthe vaporizer body.
 93. The atomizer assembly of claim 92, wherein theouter wall further comprises a base positioned approximatelyperpendicular to the two opposing short sides and the two opposing longsides, the base at least partially defining the internal volume.
 94. Theatomizer assembly of claim 93, wherein the base comprises one or moreslots, wherein air pressure caused by a flow of vaporizable materialwithin the heating portion is configured to escape through the one ormore slots.
 95. The atomizer assembly of claim 93, wherein theconnecting portion includes a retainer portion configured to bend aroundthe base to secure the heating element to the wick housing, and whereinthe base includes an aperture configured to receive the retainer portionof the connecting portion.
 96. The atomizer assembly of claim 93,further comprising: an opening opposite the base, wherein the connectingportion extends out of the opening and over the outer wall, and whereinthe wicking element is configured to pass through the opening.
 97. Theatomizer assembly of claim 96, further comprising: an outer rimsurrounding the opening and extending away from the opening.
 98. Theatomizer assembly of claim 97, wherein the outer rim includes anaperture through which the connecting portion of the heating element isconfigured to pass through.
 99. The atomizer assembly of claim 98,wherein an outer surface of the wick housing includes a recessed channelfor securing the connecting portion of the heating element, the recesschannel aligning with the aperture.
 100. The atomizer assembly of claim97, wherein the outer wall comprises a capillary feature, the capillaryfeature comprises a curved surface formed at an intersection between atleast one of the two opposing long sides and the outer rim.
 101. Theatomizer assembly of claim 100, wherein the curved surface has a radiusthat is sufficient to break tangency points between an outer surface andthe outer rim.
 102. The atomizer assembly of claim 100, wherein thecapillary feature is configured to cause an abrupt change in capillarypressure between the heating element and the wick housing to therebyprevent a vaporizable material from flowing beyond the capillaryfeature.
 103. The atomizer assembly of claim 100, wherein the capillaryfeature is positioned within a cutout in the outer wall, the cutoutconfigured to space the heating element from the outer wall, therebypreventing excess heat from contacting the outer wall.
 104. The atomizerassembly of claim 92, wherein at least one of the two opposing shortsides comprises a chip recess configured to receive an identificationchip.
 105. The atomizer assembly of claim 104, wherein the chip recesscomprises at least two walls configured to surround and retain theidentification chip.
 106. The atomizer assembly of claim 92, wherein therecess is positioned proximate to an intersection between a long side ofthe two opposing long sides and a short side of the two opposing shortsides.
 107. The atomizer assembly of claim 92, wherein each of the twoopposing long sides includes two recesses.
 108. A method of forming anatomizer assembly for a vaporizer device, the method comprising:coupling a heating element to a wick housing configured to surround aheating portion of the heating element, the wick housing comprising: anouter wall comprising two opposing short sides and two opposing longsides, the two opposing long sides having formed therein a recessedchannel configured to receive a connecting portion of the heatingelement, a base positioned approximately perpendicular to the twoopposing short sides and the two opposing long sides, an internal volumeformed by the outer wall and the base, the internal volume surroundingthe heating portion of the heating element, and an opening opposite thebase, wherein the heating portion of the heating element passes throughthe opening.
 109. The method of claim 108, wherein the coupling includessliding the connecting portion of the heating element in the recessedchannel formed in the outer wall of the wick housing.
 110. An atomizerassembly for a vaporizer cartridge, the atomizer assembly comprising: awick housing comprising an outer wall at least partially defining aninternal volume configured to receive a wicking element and at least aheating portion of a heating element, the heating element alsocomprising a connecting portion configured to extend out of the internalvolume and over the outer wall such that the outer wall is positionedbetween the heating portion and the connecting portion, the outer wallcomprising two opposing short sides and two opposing long sides. 111.The atomizer assembly of claim 110, wherein each of the two opposinglong sides having formed therein a recess configured to releasablycouple the vaporizer cartridge to a corresponding feature of a vaporizerbody.